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Pinpoint Test E: The Air Conditioning (A/C) Is Inoperative

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. E1 USE THE RECORDED DTCs FROM THE PCM SELF-TEST 
    • Using the recorded results from the PCM self-test:
    • Is DTC P2611, P1459, P1464, P0537, P0538 or P0645 present? 
    1. YES  : REFER to INTRODUCTION -- HYBRID ENGINES article to continue diagnosis.
    2. NO  : Go to  E2.
  2. E2 CHECK THE REFRIGERANT PRESSURE 
    • Key in OFF position.
    • Connect the manifold set to the service ports.
    • Is the pressure 345-1,724 kPa (50-250 psi)? 
    1. YES  : Go to  E3.
    2. NO  : CHECK the system for refrigerant leaks. REFER to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
  3. E3 CHECK THE A/C CLUTCH RELAY 
    • Disconnect: A/C Clutch Relay C1008
    • Carry out the A/C clutch relay component test. Refer to COMPONENT TESTING article.
    • Is the A/C clutch relay OK? 
    1. YES  : Go to  E4.
    2. NO  : INSTALL a new A/C clutch relay. TEST the system for normal operation.
  4. E4 CHECK CIRCUIT 1483 (WH/PK) FOR VOLTAGE 
      Fig 1: Checking Circuit For Voltage
      GF0025701Courtesy of FORD MOTOR CO.
    • Measure the voltage between A/C compressor clutch relay C1008-3, circuit 1483 (WH/PK), harness side and ground.
    • Is the voltage greater than 10 volts? 
    1. YES  : Go to  E5.
    2. NO  : INSPECT battery junction box (BJB) fuse 16 (15A) for an open. If OK, REPAIR the circuit. TEST the system for normal operation.
  5. E5 CHECK CIRCUIT 321 (GY/WH) FOR AN OPEN 
    • Disconnect: A/C Compressor Clutch C100
      • Fig 2: Connecting Fused Jumper Wire
      GF0025702Courtesy of FORD MOTOR CO.
    • Connect a fused (5A) jumper wire between A/C clutch relay C1008-3, circuit 1483 (WH/PK), harness side and A/C clutch relay C1008-5, circuit 321 (GY/WH), harness side.
      • Fig 3: Checking Circuit For Open
      GF0025703Courtesy of FORD MOTOR CO.
    • Measure the voltage between A/C compressor C100-1, circuit 321 (GY/WH), harness side and ground.
    • Is the voltage greater than 10 volts? 
    1. YES  : REMOVE the jumper wire. Go to  E6 .
    2. NO  : REPAIR the circuit. TEST the system for normal operation.
  6. E6 CHECK CIRCUIT 57 (BK) FOR AN OPEN 
      Fig 4: Checking Circuit For Open
      GF0025704Courtesy of FORD MOTOR CO.
    • Measure the resistance between A/C compressor clutch C100-2, circuit 57 (BK), harness side and ground.
    • Is the resistance less than 5 ohms? 
    1. YES  : Go to  E7.
    2. NO  : REPAIR the circuit. TEST the system for normal operation.
  7. E7 CHECK THE CLUTCH AIR GAP 
    • Measure the A/C compressor clutch air gap at 3 equally spaced locations between the clutch hub and the A/C compressor clutch pulley.
    • Is the A/C compressor clutch air gap greater than 0.76 mm (0.030 in)? 
    1. YES  : ADJUST the A/C compressor clutch air gap to within specification. REFER to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article. TEST the system for normal operation.
    2. NO  : INSTALL a new A/C compressor clutch coil. REFER to CLIMATE CONTROL article. TEST the system for normal operation.
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