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Test Procedure

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. KM1 VERIFY THE A/C AND DEFROST WERE OFF DURING THE SELF-TEST 
    • Verify the A/C and defrost were off during the self-test.

    Was the A/C and defrost off during the self-test? 

    Yes No
    GO to  KM2. TURN off the A/C and DEFROST, then REPEAT the self-test.
  2. KM2 DTCS P0645, P1459, P1464, P2515, P2521, P2524 AND P2611: CHECK FOR SELFTEST DTCS 

    Are any of the following DTCs present during PCM or TCM self-test: P0645, P1459, P1464, P2515, P2521, P2524, or P2611? 

    Yes No
    For KOEO and KOER DTC P0645, GO to  KM3.
    For continuous memory DTC P0645, GO to  KM8.
    For KOEO and KOER DTC P1459, GO to  KM10.
    For KOEO and KOER DTC P1464, GO to  KM14.
    For KOEO and KOER DTC P2515, GO to  KM17.
    For KOEO and KOER DTCs P2521 and P2524, GO to  KM19.
    For KOEO and KOER DTC P2611, GO to  KM21.
    For continuous memory DTC P2611, GO to  KM26.
    For continuous memory DTCs P2521 and P2524, GO to  KM28.    		 The concern is elsewhere. RETURN to SYMPTOM CHARTS for further direction.
  3. KM3 KOEO AND KOER DTC P0645: CHECK THE VPWR VOLTAGE TO CLUTCH RELAY 
    • A/CC Relay connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) A/CC Relay Connector, Harness Side ( - )
      VPWR - Pin 2 Ground

    Is the voltage greater than 10.5 V? 

    Yes No
    Key in OFF position.
    GO to  KM4.    		 REPAIR the open circuit.
  4. KM4 CHECK THE A/CC RELAY 
    • Measure the resistance between either pin 1 or pin 85 and all the other pins of the relay. One measurement must be between 40 and 120 ohms, with the other measurements being greater than 10,000 ohms.

    Are all resistance checks OK? 

    Yes No
    GO to  KM5. INSTALL a new A/CC relay.
  5. KM5 CHECK THE A/CC CIRCUIT FOR A SHORT TO POWER IN THE HARNESS 
    • PCM connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) A/CC Relay Connector, Harness Side ( - )
      A/CC - Pin 1 Ground

    Is the voltage less than 1 V? 

    Yes No
    Key in OFF position.
    GO to  KM6.    		 REPAIR the short circuit.
  6. KM6 CHECK THE A/CC CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS 
    • Measure the resistance between:
      ( + ) A/CC Relay Connector, Harness Side ( - )
      A/CC - Pin 1 Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    GO to  KM7. REPAIR the short circuit.
  7. KM7 CHECK THE A/CC CIRCUIT FOR AN OPEN IN THE HARNESS 
    • Measure the resistance between:
      ( + ) A/CC Relay Connector, Harness Side ( - ) PCM Connector, Harness Side
      A/CC - Pin 1 A/CC - Pin B25

    Is the resistance less than 5 ohms? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . REPAIR the open circuit.
  8. KM8 CONTINUOUS MEMORY DTC P0645: CHECK THE A/CC CIRCUIT FOR AN INTERMITTENT SHORT TO GROUND 
    NOTE: The air conditioning clutch clicks on when a fault is detected.
    • Key ON, engine OFF.
    • Check the A/CC circuit for short to ground while carrying out the following:
      • Shake, wiggle, and bend the A/CC circuit(s).
      • Lightly tap on the Air Conditioning Clutch to simulate road shock.

    Is a fault indicated? 

    Yes No
    Key in OFF position.
    REPAIR as necessary.
    CLEAR the DTCs.
    START the engine.
    TURN on the A/C.
    WAIT 15 seconds.
    TURN off the A/C.
    REPEAT the self-test.
    REFER to SYMPTOM CHARTS .    		 GO to  KM9.
  9. KM9 CHECK THE A/CC CIRCUIT FOR AN INTERMITTENT OPEN OR SHORT TO POWER 
    NOTE: The air conditioning clutch clicks off when a fault is detected.
    • Key ON, engine OFF.
    • Enter output test mode. Refer to OUTPUT TEST MODE (OTM) .
    • Command the outputs ON.
    • Check the A/CC circuit for an open or short to power while carrying out the following:
      • Shake, wiggle, and bend the A/CC circuit(s).
      • Shake, wiggle, and bend the VPWR circuit to the Air Conditioning Clutch relay.
      • Lightly tap on the Clutch relay to simulate road shock.

    Is a fault indicated? 

    Yes No
    Key in OFF position.
    REPAIR as necessary.
    CLEAR the DTCs.
    START the engine.
    TURN on the A/C.
    WAIT 15 seconds.
    TURN off the A/C.
    REPEAT the self-test.
    REFER to SYMPTOM CHARTS .    		 Key in OFF position.
    Unable to duplicate or identify the fault at this time.
    GO to Pinpoint Test Z .
  10. KM10 KOEO AND KOER DTC P1459: CHECK IGN START/RUN VOLTAGE TO A/C HEATER MODE SWITCH 
    • A/C Heater Mode Switch connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) A/C Heater Mode Switch Connector, Harness Side ( - )
      IGN START/RUN Ground

    Is the voltage greater than 10.5 V? 

    Yes No
    Key in OFF position. Key in OFF position.
    GO to  KM11. IGN START/RUN circuit fault. CHECK the condition of the related fuse/fuse links. If OK, REPAIR the open circuit. If the fuse/fuse link is damaged, CHECK the circuit for short to ground before replacing.
  11. KM11 CHECK THE A/C HEATER MODE SWITCH 
    • Carry out the following resistance measurement with the A/C heater mode switch in the OFF, MAX A/C, and A/C RECIRC position.
    • Measure the resistance between:
      ( + ) A/C Heater Mode Switch Connector, Component Side ( - ) A/C Heater Mode Switch Connector, Component Side
      IGN START/RUN A/CRSW

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  KM12. INSTALL a new A/C Heater Mode Switch.
  12. KM12 CHECK A/CRSW CIRCUIT CONTINUITY 
    • PCM connector disconnected.
    • Measure the resistance between:
      ( + ) A/C Heater Mode Switch Connector, Harness Side ( - ) PCM Connector, Harness Side
      A/CRSW A/CRSW - Pin B2

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  KM13. REPAIR the open circuit.
  13. KM13 CHECK THE A/CRSW CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS 
    • Measure the resistance between:
      ( + ) A/C Heater Mode Switch Connector, Harness Side ( - )
      A/CRSW Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . REPAIR the short circuit to GND.
  14. KM14 KOEO AND KOER DTC P1464: VERIFY THE A/C AND DEFROST WERE OFF DURING THE SELF-TEST 
    • Verify the A/C and defrost were off during the self-test.

    Was the A/C and defrost off during the self-test? 

    Yes No
    GO to  KM15. TURN OFF the A/C and DEFROST, then REPEAT the self-test.
  15. KM15 CHECK THE A/C HEATER MODE SWITCH 
    • A/C Heater Mode Switch connector disconnected.
    • Check for self-test DTCs.

    Is DTC P1464 present? 

    Yes No
    GO to  KM16. REFER to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS - HYBRID to check the operation of the climate control mode switch.
  16. KM16 CHECK THE A/CCS CIRCUIT FOR A SHORT TO POWER IN THE HARNESS 
    • PCM connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) PCM Connector, Harness Side ( - )
      A/CCS - Pin B15 Ground

    Is the voltage less than 1 V? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . REPAIR the short circuit to PWR.
  17. KM17 KOEO AND KOER DTC P2515: CHECK THE ACP PID WITH THE SWITCH DISCONNECTED 
    • A/CHPSW connector disconnected.
    • Access the PCM and monitor the ACP PID.

    Is the PID state CLOSED? 

    Yes No
    Key in OFF position. Key in OFF position.
    GO to  KM18. REFER to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS - HYBRID to check A/C refrigerant pressure.
  18. KM18 CHECK THE A/CPSW CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS 
    • PCM connector disconnected.
    • Measure the resistance between:
      ( + ) A/CHPSW Connector, Harness Side ( - )
      A/CPSW - Pin 1 Ground

    Is the resistance less than 10K ohms? 

    Yes No
    REPAIR the short circuit to GND. INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) .
  19. KM19 KOEO AND KOER DTCS P2521 AND P2524: CHECK THE A/C HEATER MODE SWITCH 
    • A/C Heater Mode Switch connector disconnected.
    • Check for self-test DTCs.

    Is DTC P2524 present? 

    Yes No
    GO to  KM20. REFER to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS - HYBRID to check the operation of the climate control mode switch.
  20. KM20 CHECK THE A/CFDS CIRCUIT FOR A SHORT TO POWER IN THE HARNESS 
    • PCM connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) PCM Connector, Harness Side ( - )
      A/CFDS - Pin B3 Ground

    Is the voltage less than 1 V? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . REPAIR the short circuit to PWR.
  21. KM21 KOEO AND KOER DTC P2611: CHECK THE VOLTAGE TO A/CRDV 
    • A/CRDV Solenoid connector disconnected. (also referred to as Passenger A/C Zone Valve)
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) A/CRDV Solenoid Connector, Harness Side ( - )
      VPWR - Pin 1 Ground

    Is the voltage greater than 10.5 V? 

    Yes No
    Key in OFF position.
    GO to  KM22.    		 REPAIR the open circuit.
  22. KM22 CHECK FOR A/CRDV CIRCUIT CYCLING 
    • Connect a non-powered test lamp between:
      ( + ) A/CRDV Solenoid Connector, Harness Side ( - ) A/CRDV Solenoid Connector, Harness Side
      VPWR - Pin 1 A/CRDV - Pin 2
    • Enter output test mode. Refer to OUTPUT TEST MODE (OTM) .
    • Command the outputs ON.
    • Enter output test mode. Refer to OUTPUT TEST MODE (OTM) .
    • Command the outputs OFF.

    Does the test lamp illuminate on and off when the output(s) is commanded on and off? 

    Yes No
    INSTALL a new A/CRDV solenoid. Key in OFF position.
    GO to  KM23.
  23. KM23 CHECK THE A/CRDV CIRCUIT FOR A SHORT TO POWER IN THE HARNESS 
    • PCM connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) A/CRDV Solenoid Connector, Harness Side ( - )
      A/CRDV - Pin 2 Ground

    Is the voltage less than 1 V? 

    Yes No
    Key in OFF position.
    GO to  KM24.    		 REPAIR the short circuit to PWR.
  24. KM24 CHECK THE A/CRDV CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS 
    • Measure the resistance between:
      ( + ) A/CRDV Solenoid Connector, Harness Side ( - )
      A/CRDV - Pin 2 Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    GO to  KM25. REPAIR the short circuit to GND.
  25. KM25 CHECK THE A/CRDV CIRCUIT FOR AN OPEN IN THE HARNESS 
    • Measure the resistance between:
      ( + ) A/CRDV Solenoid Connector, Harness Side ( - ) PCM Connector, Harness Side
      A/CRDV - Pin 2 A/CRDV - Pin T22

    Is the resistance less than 5 ohms? 

    Yes No
    INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . REPAIR the open circuit.
  26. KM26 CONTINUOUS MEMORY DTC P2611: CHECK THE A/CRDV CIRCUIT FOR AN INTERMITTENT OPEN OR SHORT TO GROUND 
    • Access the PCM and monitor the ACRDV_F PID.
    • Check the A/CRDV and VPWR circuit for concern while carrying out the following. Note that a fault is indicated by a sudden change in the ACRDVF PID.
    • Shake, wiggle, and bend the ACRDV circuit(s).
    • Shake, wiggle, and bend the VPWR circuit(s).

    Is a fault indicated? 

    Yes No
    Key in OFF position.
    ISOLATE the fault and REPAIR as necessary.    		 GO to  KM27.
  27. KM27 CHECK THE A/CRDV CIRCUIT FOR A SHORT TO POWER 
    • A/CRDV Solenoid connector disconnected.
    • Connect a non-powered test lamp between the A/CRDV circuit and ground.
    • Key ON, engine OFF.
    • Observe the test lamp for an indication of a fault while completing the following. Note that the lamp turns on when a fault is detected.
    • Shake, wiggle, and bend the ACRDV circuit(s).

    Is a fault indicated? 

    Yes No
    ISOLATE the fault and REPAIR as necessary. Key in OFF position.
    Unable to duplicate or identify the fault at this time.
    GO to Pinpoint Test Z .
  28. KM28 CONTINUOUS MEMORY DTCS P2521 AND P2524: CHECK THE A/CCS AND A/CFDS CIRCUITS FOR INTERMITTENT FAULTS 
    • Key ON, engine OFF.
    • Access the PCM and monitor the ACCS and ACFDS_P PIDs.
    • Check for intermittent circuit failures while carrying out the following (a fault will be indicated by a sudden change in the ACCS and ACFDS_P PID):
    • Shake, wiggle, and bend the ACCS and ACFDS_P circuit(s).

    Is a fault indicated? 

    Yes No
    Key in OFF position. Key in OFF position.
    ISOLATE the fault and REPAIR as necessary. GO to Pinpoint Test Z .
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