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Climate Control System: Notes

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.
SPECIAL TOOL(S)

G04621498Courtesy of FORD MOTOR CO.
 Worldwide Diagnostic System (WDS)
Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool
G04621499Courtesy of FORD MOTOR CO.
 R-134a Manifold Gauge Set
176-R032A or equivalent
G04621500Courtesy of FORD MOTOR CO.
 Connector, Refrigerant Pressure Line
412-093 (T94P-19623-E)
G04621501Courtesy of FORD MOTOR CO.
 Set, A/C Fittings
412-DS028 (D93L-19703-B) or equivalent
G04621502Courtesy of FORD MOTOR CO.
 Refrigerant Leak Detector
216-00001 or equivalent
G04621503Courtesy of FORD MOTOR CO.
 Pressure Tester
014-R1072 or equivalent
G04621504Courtesy of FORD MOTOR CO.
 73111 Automotive Meter
105-R0057 or equivalent
Fig 1: Climate Control System Vacuum Schematic
G04621505Courtesy of FORD MOTOR CO.
Fig 2: Identifying Function Selector Switch Vacuum Connector Pinouts
G04621506Courtesy of FORD MOTOR CO.

Function Selector Switch Vacuum Application Table - Hybrid 

NOTE: A leak in the vacuum control circuit may occur during acceleration (slow leak), may exist at all times (large leak) or may exist only when specific functions are selected (indicating a leak in that portion of the circuit). The vacuum hoses used in the passenger compartment control circuit are constructed from PVC plastic material. The vacuum hoses used in the engine compartment are constructed of Hytrel®. Because of the materials used, never pinch off the vacuum hoses to locate a leak during diagnosis. A golf tee can be used as a plug when it is necessary to plug one end of the vacuum hose for leak test purposes.
FUNCTION SELECTOR SWITCH VACUUM APPLICATION TABLE

Port Color Function Function Selector Switch Position
MAX A/C A/C Recirc A/C Panel OFF Panel/Floor Floor Floor/DEF DEF
1 WH Recirc V V NV NV V NV NV NV NV
2 YE Defrost V V V V V V V NV NV
3 RD Floor NV NV NV NV V V V V NV
4 OG Panel/Floor V V V V NV V NV NV NV
5 BK Source V V V V V V V V V
6 - Not used N/A N/A N/A N/A N/A N/A N/A N/A N/A
V=Vacuum
NV=No vacuum
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