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Pinpoint Test M: The Defrost System Is Inoperative - Fusion, MILAN

WARNING: This page is about a different car, the 2010 Mercury Milan, 2010 Lincoln MKZ, and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Use the correct probe adapter(s) from the Flex Probe Kit when making measurements. Failure to use the correct probe adapter(s) may damage the connector.
  1. M1 CHECK THE REAR WINDOW DEFROST GRID VOLTAGE 
    • Disconnect: Rear Window Defrost Grid Power.
    • Start the engine.
    • Activate the rear defrost switch and measure the voltage between rear window defrost grid power C402A-1, circuit CRD06 (BN/YE), harness side and ground.
      Fig 1: Measuring Voltage Between Rear Window Defrost Grid Power C402A-1, Circuit CRD06 (BN/YE), Harness Side And Ground
      G06070954Courtesy of FORD MOTOR CO.
    • Is the voltage greater than 10 volts? 
    • Yes:  GO to  M2.
    • No:  GO to  M3.
  2. M2 CHECK THE REAR WINDOW DEFROST GRID GROUND 
    • Ignition OFF.
    • Disconnect: Rear Window Defrost Grid Ground C402B.
    • Measure the resistance between rear window defrost grid ground C402B-1, circuit GD147 (BK/VT) and ground.
      Fig 2: Measuring Resistance Between Rear Window Defrost Grid Ground C402B-1, Circuit GD147 (BK/VT) & Ground
      G06070955Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes:  CARRY OUT the Grid Wire Test in this section. REPAIR the rear window defrost grid or INSTALL a new rear window glass. REFER to WINDOW GRID WIRE REPAIR . TEST the system for normal operation. 
    • No:  REPAIR the circuit. TEST the system for normal operation.
  3. M3 CHECK THE POWER TO THE RELAY 
    • Ignition OFF.
    • Disconnect: Rear Window Defrost Relay.
    • Ignition ON.
    • Measure the voltage between rear window defrost relay socket pin 86 and pin 30, harness side and ground.
      Fig 3: Measuring Voltage Between Rear Window Defrost Relay Socket Pin 86 & Pin 30, Harness Side & Ground
      G06259620Courtesy of FORD MOTOR CO.
    • Is the voltage greater than 10 volts? 
    • Yes:  GO to  M4.
    • No:  VERIFY Battery Junction Box (BJB) fuse 6 (40A) and Smart Junction Box (SJB) fuse 45 (5A) are OK. If OK, REPAIR the circuit. TEST the system for normal operation.

      If not OK, REFER to the appropriate SYSTEM WIRING DIAGRAMS article to identify the possible causes of the circuit short. REPAIR the circuit. TEST the system for normal operation.

  4. M4 CHECK THE HVAC MODULE 
    NOTE: The following step uses a test light to simulate normal circuit loads. Use only the test light recommended in SPECIAL TOOLS TABLE  or equivalent. To avoid connector terminal damage, use the Flex Probe Kit for the test light probe connection to the vehicle. Do not use the test light probe directly on any connector.
    • Start the engine.
    • Activate the rear window defrost switch.
    • Connect a 12-volt incandescent test light between rear window defrost relay socket pin 85, circuit CH122 (WH/OG) and rear window defrost relay socket pin 86.
      Fig 4: Connecting 12-Volt Incandescent Test Light Between Rear Window Defrost Relay Socket Pin 85, Circuit CH122 (WH/OG) & Rear Window Defrost Relay Socket Pin 86
      G06070957Courtesy of FORD MOTOR CO.
    • Does the test light illuminate? 
    • Yes:  GO to  M5.
    • No:  If equipped with navigation system, GO to  M6. If not equipped with navigation system, GO to  M7.
  5. M5 CHECK THE REAR WINDOW DEFROST RELAY 
    • Yes:  REPAIR open in circuit CRD06 (BN/YE). CLEAR the DTCs. TEST the system for normal operation.
    • No:  INSTALL a new rear window defrost relay. CLEAR the DTCs. TEST the system for normal operation.
  6. M6 CHECK THE REAR WINDOW DEFROST SWITCH (CC_SW_R_DEF) PID 
    • Ignition ON.
    • Enter the following diagnostic mode on the scan tool: DataLogger - FCIM  .
    • Monitor the FCIM  CC_SW_R_DEF PID while pressing and releasing the rear window defrost switch.
    • Does the PID agree with the rear window defrost switch status? 
    • Yes:  GO to  M7.
    • No:  INSTALL a new FCIM  . CLEAR the DTCs. TEST the system for normal operation.
  7. M7 CHECK CIRCUIT CH122 (WH/OG) FOR AN OPEN 
    • Ignition OFF.
    • Disconnect: HVAC Module - Electronic Manual Temperature Control (EMTC) C2357A or HVAC Module - Dual Automatic Temperature Control (DATC) C2356A.
    • Measure the resistance between rear window defrost relay socket pin 85, circuit CH122 (WH/OG), harness side and HVAC module - EMTC C2357A-12 or HVAC Module - DATC C2356A-12, circuit CH122 (WH/OG), harness side.
      Fig 5: Measuring Resistance Between Rear Window Defrost Relay Socket Pin 85 & HVAC Module - EMTC C2357A-12 Or HVAC Module - DATC C2356A-12
      G06259630Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes:  GO to  M8.
    • No:  REPAIR the circuit. TEST the system for normal operation.
  8. M8 CHECK FOR CORRECT HVAC MODULE OPERATION 
    • Disconnect all HVAC module electrical connectors.
    • Check for:
      • corrosion.
      • pushed-out pins.
    • Connect all HVAC module electrical connectors and make sure they seat correctly.
    • Operate the system and verify the concern is still present.
    • Is the concern still present? 
    • Yes:  INSTALL a new HVAC module. TEST the system for normal operation.
    • No:  The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. TEST the system for normal operation.
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