BACK TO CHAPTER INDEX < FORD FIESTA ST150 2005.25 WRM 4412-00-41 Climate Control System - General Information TO MODEL INDEX 412-00... SECTION 412-00 Climate Control System - General Information VEHICLE APPLICATION: 2005.25 Fiesta CONTENTS SPECIFICATIONS Specifications. DIAGNOSIS AND TESTING Climate Control System Inspection and Checking Refrigerant Circuit - Quick Check ‘Symptom Chart System Checks Component Tests GENERAL PROCEDURES Air Conditioning (A/C) Clutch Air Gap Adjustment At Conatioring (AIC) System Reeovery, Evacuetion end Cherging.. Refrigerant Oil Adding... Air Distribution System Cleaning Contaminated Refrigerant Handling Spring Lock Coupling .....:::nunnnnnunnnnnunnnnnnvenn Electronic Leak Detection ...... hose Fluorescent Dye Leak Detection .. Vacuum Leak Detection.......... (34.6286) (34 620 2) (34.621 1) (34.620 8) (346207) (34 620 3) 11/2004 2005.25 Fiesta, PAGE 412-00-2 412-00-3 412-00-3 412-00-3 412-00-4 412-00-5 412-00-36 412-00-37 412-00-38 412-00-41 41-00-42 412-00-44 41-00-45 412-00-47 412-00-48 412-00-49 >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Gia12.00.2 Climate Control System - General Information 412.002 SPECIFICATIONS Lubricants, sealants and adhesives [Material ‘Specification Refrigerant Risda WSH-M17B19-A Refrigerant oil WSH-M1C231-8 Refrigerant fill quantities Grams Air conditioning 6504 13 Air conditioning (vehicles with 1.6L Duratorg-TDCi (DV) diesel engine) 5202 13 Refrigerant oil fill quantities millilitres ‘Air conditioning 207 [Air conditioning (vehicles with 7.6L Duratorg-TDG! (DV) diesel engine) 200 Addition of refrigerant oil when new components are installed millilitres Air conditioning compressor (if the amount of refrigerant oll taken from the add 90. [compressor is less than 90 mi) Air conditioning compressor (vehicles with 1.6L Duratorq-TDCi (DV) diesel add 50 Jengine) (if the amount of refrigerant oll taken from the compressor is less than A fom A ‘Air conditioning compressor (if the amount of refrigerant oll taken fromthe _ |Add same quantity + 30 compressor is between 90 ml and 150 mi)) Air conditioning compressor (vehicles with 1.6L Duratorg-TOCi (DV) diesel _[Add same quantity + 30 lengine) (if the amount of refrigerant oil taken from the compressor is between] 50 ml and 150 ml)) Air conditioning compressor (if the amount of refrigerant oll taken fromthe _ | Add the same quantity [compressor is more than 150 ml) Air conditioning condenser add 30. [Air conditioning evaporator add 90. Air conditioning evaporator (vehicles with 1.6L Durator-TOCI (DV) diesel add 50. lengine) Renewal of all ines ‘Add same quantity +2 Renewal of all ines and components ‘add 0. Always, if refrigerant was drained. ‘Add the same quantity, [Accumulator/dehydrator_ ‘Add same quantity +90. Accumulator/dehydrator (vehicles with 1.6L Duralorg-TDCl (DV) diesel en- | Add same quantity +50. Igine) Air conditioning clutch rm [Clutch gap, AC compressor 0,35- 0.75 Tightening torques Description Nm Ibift Ib/in Bolt, A/C compressor drive plate 43 10 - .G105769 en 11/2004 2005.25 Fiesta < >BACK TO CHAPTER INDEX BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Gia12.00-4 Climate Control System - General Information 412.004 DIAGNOSIS AND TESTING (Continued) The temperature cifference should be more than 20°, depending on the ambient temperature. If the temperature difference is less, check the condenser for contamination or damage to the fins as well as operation of the radiator fan + The low pressure line between the fixed orifice tube and the evaporator must be cold from the installation position of the fixed orifice tube. Depending on the weather, the line may also be iced up on the outside. + The low pressure line between the evaporator and the A/C compressor should be cold, including the dehydrator. Evaporator outlet temperature test In order to check the A/C output, the temperature of the evaporator outlet line must be measured. The following preparations must be taken for this, purpose: + Open all windows. + Set the air distribution to the defrost/dashboard position and open all the ventilation nozzles. AL {DONT switch on recirculated at + Select lowest blower switch setting, + Select lowest temperature setting. NOTE: Temperature measurements cannot be performed using a non-contact thermometer. Incorrect measurements result owing to surface reflection Connect temperature sensor (Fluke 80 PK-8) to the refrigerant line from the evaporator to the dehydrator in the area of the dehydrator (metal line). Connect the temperature sensor to the muttimeter. Start the engine and allow it to run at idle speed for several minutes. Switch on the air-conditioning system If the temperature measured is 2° C or lower (vehicles with automatic transmission: 5° C or lower) the A/C system is OK. If the temperature is higher, the A/C system may be under-filled For further information, refer to Air Conditioning (AIC) System Recovery, Evacuation and Charging in this section. Frequent faults and their causes ‘Should a customer express concern about poor cooling performance of the A/C system it must be ensured that the temperature control valve actuation is OK + No or poor cooling performance: - Blockage or restriction in one of the refrigerant lines or in the dehydrator: By comparing temperatures at the refrigerant lines or at the dehydrator, the location of the blockage of restriction can easily be identified. The blockage or restriction is located at the point where the temperature difference is identified. Note: A temperature difference in the area of the fixed orifice tube is normal. Once the location of the blockage or restriction has been detected, check the relevant component and renew if necessary. + Sudden poor cooling performance After the compressor has been switched off for approx. 5 minutes, the cooling performance returns to normal: Fixed orifice tube iced up. The cause for an iced-up fixed orifice tube is moisture in the system. In order to ensure that moisture is completely removed from the refrigerant circuit, evacuation time must be extended to 2-3 hours and the dehydrator must be renewed. For further information, REFER to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this After three minutes, measure the surface section temperature of the evaporator outlet line. Symptom Chart ‘Symptom Possible Sources Action /-Blower motor faulty / inoperative |-Fuse(s) /*Circuit(s) Blower motor |* Blower switch Blower resistor assembly |- GO to Pinpoint Test A gS 8800en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX BACK TO CHAPTER INDEX Gia12.00-6 DIAGNOSIS AND TESTING (Continued) Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412-00-6 TEST CONDITIONS DETAILS/RESULTSIACTIONS = The blower motor is only inoperative in switch position 4: GO to AB ‘A2: CHECK FUSE F49 ignition switch in position 0. HECK fuse F49 (CJB) + Is the fuse OK? Yes GO to AS >No INSTALL A NEW fuse F49 (30 A) CHECK the operation of the system ifthe fuse blows again, LOCATE and REPAIR the short using the Wiring Dia- grams ‘A3: CHECK THE VOLTAGE AT FUSE F49 ‘onnect fuse F49 (CJB). [2 ignition switch in position Il [3 |Measure the voltage between fuse F49 (30 A) ‘and ground. + Does the meter display battery voltage? Yes GOto Ad >No REPAIR the voltage supply to fuse F49 using the Wiring Diagrams. CHECK the operation of the system. ‘A4: CHECK VOLTAGE AT THE BLOWER MOTOR a ree [1 jignition switch in position 0. [2 [Disconnect connector C322 from blower motor. [3 |ignition switch in position II [4 |Measure the voltage between the blower motor, connector C322, pin 1, circuit 15-FA18 (GNIOG), wiring harness side and ground. vFE002@910 * Does the meter display battery voltage? Yes GO to AS = No qe en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTS/AC TIONS LOCATE and REPAIR break in circuit 16-FA18 (GN/OG), between blower motor and fuse F49 using the Wiring Diagrams. CHECK the operation of the system ‘AS: CHECK GROUND CONNECTION OF BLOWER MOTOR o4 Viel 0028011 ignition switch in position 0. set the blower switch to position 4. jeasure the resistance between the blower motor, connector C322, pin 2, circuit 31S-FA18 (BK/RD), wiring harness side and ground. + Is a resistance of less than 2 Ohm registered? Yes RENEW the blower motor. CHECK the operation of the system No GO to A CIRCUIT 6: CHECK CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN ‘connect connector C324 from blower switch, [2 Measure the resistance between the blower motor, connector C322, pin 2, circuit 318-FA18 (BK/RD), wing harness side and the blower switch, connector C324, pin 1, circuit 31S-FA33 (BK/OG), wiring harness side \vFE0028912 + Isa resistance of less than 2 Ohm registered? Yes GO to AT = No. 6115900 en 11/2004 2005.25 Fiesta, >FORD FIESTA ST150 2005.25 WRM BACK TO CHAPTER INDEX TO MODEL INDEX Gia12.00-8 Climate Control System - General Information 412.008 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTS/ACTIONS LOCATE and REPAIR the break in circuit 31S-FA18 (BK/RD) between the blower motor and soldered connection $269 using the Wiring Diagrams. CHECK the operation of the system ‘AT: CHECK THE GROUND CONNECTION OF THE BLOWER SWITCH [1 |Measure the resistance between the blower ‘switch, connector C324, pin 3, circuit 31-FA25 (BK), wiring harness side and ground. \vFE0028894 + Is a resistance of less than 2 Ohm registered? 3 Yes A INSTALL A NEW blower switch a CHECK the operation of the system, No LOCATE and RECTIFY the break in circuit 31-F A265 (BK) between the blower switch and ground connection G30 using the Wiring Diagrams. CHECK the operation of the sys- tem ‘Ag: CHECK CIRCUIT BETWEEN THE BLOWER MOTOR AND THE BLOWER SWITCH FOR OPEN CIRCUIT 1 Jignition switch in position O. 2 [Disconnect connector C324 from blower switch [B)pisconnect connector €322 from blower motor. [Measure the resistance between the blower motor, connector C322, pin 2, circuit 31S-FA18 (GK/RD), wiring harness side and the blower switch, connector C324, pin 1, circuit 318-FA33 (K/06), wiring harness side. 1 \vFE0028012 + Is a resistance of less than 2 Ohm registered? 3 Yes .G115900 en 11/2004 2005.25 Fiesta < >BACK TO CHAPTER INDEX < 412-00-9 Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.00. DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTS/AC TIONS INSTALL A NEW blower switch CHECK the operation of the system. No LOCATE and RECTIFY the break in circuit 31S-FA33 (BK/OG) between soldered con- nection $269 and the blower switch using the Wiring Diagrams. CHECK the operation of the system 'A9: CHECK VOLTAGE AT BLOWER RESISTOR ‘ASSEMBLY oo \vFE0028913 ignition switch in position 0. [2 [Disconnect connector C323 from blower resis- tor assembly. et the blower switch to position 0. ignition switch in position I leasure the voltage between the blower re- sistor, connector C323, pin 4, circuit 31S-FA1 (BK/BU), wiring hamess side and ground. + Does the meter display battery voltage? Yes GO to A10 No LOCATE and REPAIR the break in circuit 31S-FA1 (BK/BU) between soldered con- nection $269 and the blower resistor as- sembly using the Wiring Diagrams. CHECK the operation of the system. A10: CHECK THE GROUND CONNECTION OF BLOWER RESISTOR ASSEMBLY - STAGE 1 nition switch in position O. 2 [Set the blower switch to position 1 6115900 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Gia12.00-10 DIAGNOSIS AND TESTING (Continued) Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-10 TEST CONDITIONS DETAILS/RESULTSIACTIONS \VE0028918 [8 Measure the resistance between the blower resistor, connector C323, pin 2, circuit 31S-FA30 (BKWH) and ground. + Is a resistance of less than 2 Ohm registered? Yes GO to A12 No GOto AN ‘A11: CHECK CIRCUIT BETWEEN THE BLOWER SWITCH FOR OPEN CIRCUIT RESISTOR ASSEMBLY AND THE BLOWER. \vE0028017 1 [Disconnect connector C324 from blower switch. 2 |Measure the resistance between the blower resistor assembly, connector C323, pin 2, circuit 31S-FA30 (BK/WH), wiring hamess side and the blower switch, connector C324, pin 4, circuit 31S-FA30 (BK/WH), wiring hamess side + Is a resistance of less than 2 Ohm registered? — Yes, INSTALL A NEW blower switch. CHECK the operation of the system. No LOCATE and REPAIR the break in circuit 318-FA30 (BK/WH) between the blower re- sistor assembly and the blower switch using the Wiring Diagrams. CHECK the operation of the system. ‘A12: CHECK THE GROUND CONNECTION OF BLOWER RESISTOR ASSEMBLY - STAGE 2 [Set the blower switch to position 2. gS 8800en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTS/ACTIONS oH} \vFE0028914 [2 Measure the resistance between the blower resistor assembly, connector C323, pin 1, circuit 31S-FA31 (BK/YE) and ground. + Is a resistance of less than 2 Ohm registered? Yes GO to A14 No. GO to A13 A13: CHECK CIRCUIT BETWEEN THE BLOWER SWITCH FOR OPEN CIRCUIT RESISTOR ASSEMBLY AND THE BLOWER. od \vFE0028015 4 Disconnect connector C324 from blower switch 2 |Measure the resistance between the blower a resistor assembly, connector C323, pin 1, circuit 31S-FA31 (BK/YE), wiring hamess side and the blower switch, connector C324, pin 2, circuit 318-FA31 (BK/YE), wiring harness side. + Isa resistance of less than 2 Ohm registered? Yes INSTALL A NEW blower switch CHECK the operation of the system No LOCATE and REPAIR the break in circuit 31S-FA31 (BK/YE) between the blower re- sistor assembly and the blower switch using the Wiring Diagrams. CHECK the operation of the system 14: CHECK THE GROUND CONNECTION OF BLOWER RESISTOR ASSEMBLY - STAGE 3 4 Bet the blower switch to position 3. 6115900 en 11/2004 2005.25 Fiesta, DdBACK TO CHAPTER INDEX Gia12.00-12 Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-12 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTSIACTIONS VFE0028916 [2JMeasure the resistance between the blower resistor assembly, connector ©323, pin 3, circuit 31S-FA32 (BK/BU) and ground. + Is a resistance of less than 2 Ohm registered? Yes RENEW the blower resistor assembly. CHECK the operation of the system. No GO to A15 ‘A15: CHECK CIRCUIT BETWEEN THE BLOWER SWITCH FOR OPEN CIRCUIT RESISTOR ASSEMBLY AND THE BLOWER. \vFE9028919 [Disconnect connector C324 from blower switch [2 ]Measure the resistance between the blower resistor assembly, connector C323, pin 3, circuit 31S-FA32 (BK/BU), wiring harness side and the blower switch, connector C324, pin 6, circuit 31S-FA32 (BK/BU), wiring harness side. + Is a resistance of less than 2 Ohm registered? — Yes, INSTALL A NEW blower switch CHECK the operation of the system. >No LOCATE and REPAIR the break in circuit 31S-FA32 (BK/BU) between the blower re- sistor assembly and the blower switch using the Wiring Diagrams. CHECK the operation of the system. gS 8800en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX Yes GO to B2 No INSTALL A NEW blower switch. CHECK the operation of the system. B2: CHECK CIRCUITS AT BLOWER RESISTOR ASSEMBLY FAenitn ‘switch in position 0. \isconnect connector C323 from blower resis- tor assembly. ignition switch in position II heck function of blower motor. + Does the blower motor run continuously? Yes CHECK all circuits that are connected to | soldered connection $269 for a short to ground using the Wiring Diagrams and RECTIFY any short circuit(s) found. ‘CHECK the operation of the system. No ‘CHECK all circuits between the blower re- sistor and the blower switch for a short to {ground using the Wiring Diagrams and RECTIFY any short circuit(s) found, CHECK the operation of the system. PINPOINT TEST C: AIR CONDITIONING INOPERATIVE (BLOWER MOTOR FUNCTION OK) TEST CONDITIONS DETAILS/RESULTS/ACTIONS (C1:CHECK FUSE F4 J Jgnition switch in position 0 2 CHECK fuse F4 (CB). + Is the fuse OK? Yes GO toc2 = No <— 375800 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Gla12.00-14 Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-14 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTSIACTIONS INSTALL A NEW fuse F4 (10 A). CHECK the operation of the system. if the fuse blows again, LOCATE and REPAIR the short using the Wiring Diagrams, - All except vehicles with diesel engines: In addition, CHECK and if necessary RENEW the air conditioning clutch diode. CHECK the operation of the system. (C2: CHECK THE VOLTAGE AT FUSE F4 [Connect fuse F4 (CB) [2 Measure the voltage between fuse F4 (10 A) ‘and ground. + Does the meter display battery voltage? Yes GO toc3 No REPAIR the voltage supply to fuse F4 using the Wiring Diagrams. CHECK the operation of the system C3: CHECK FUSE F12 HECK fuse F12 (CJB) + Is the fuse OK? Yes GO to C4 >No INSTALL A NEW fuse F'12 (15 A) CHECK the operation of the system. if the fuse blows again, LOCATE and REPAIR the short using the Wiring Dia- grams C4: CHECK THE VOLTAGE AT FUSE F12, onnect fuse F12 (CB). [2 lignition switch in position Il [3 |Measure the voltage between fuse F12 (15 A) ‘and ground, + Does the meter display battery voltage? Yes GOtocs >No REPAIR the voltage supply to fuse F'12 using the Wiring Diagrams. CHECK the operation of the system. (C5: CHECK FUSE F38 ignition switch in position 0. HECK fuse F38 (CJB). + Is the fuse OK? = Yes gS 8800en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX < FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Climate Control System - General Information 412.00-15 > DIAGNOSIS AND TESTING (Continued) 412-0015 TEST CONDITIONS DETAILSIRESULTS/ACTIONS GO tC No INSTALL A NEW fuse F38 (7.5 A). CHECK the operation of the system If the fuse blows again, LOCATE and REPAIR the short using the Wiring Dia- grams ‘onnect fuse F38 (CJB). 2 |gnition switch in position I 3 Measure the voltage between fuse F38 (7.5 A) and ground. C6: CHECK THE VOLTAGE AT FUSE F38 + Does the meter display battery voltage? Yes GO toC7 No REPAIR the voltage supply to fuse F38 using the Wiring Diagrams. CHECK the operation of the system. C7: CHECK THE VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY nition switch in position 0 connect air conditioning clutch relay from A socket C403 (relay box, engine compartment) [3 Measure the voltage between the air condi- tioning clutch relay, socket C403, pin 3, circuit 29-FA12 (OGIBU), wiring harness side and ground. Lis} OO \vFE0028925 + Does the meter display battery voltage? Yes GO toc8 No LOCATE and RECTIFY the break in circuit 29-FA12 (OGIBU) between the air condi- tioning clutch relay and fuse F4 using the Wiring Diagrams. CHECK the operation of the system. C8: CHECK THE CONTROL VOLTAGE AT THE AIR CONDITIONING CLUTCH RELAY “ignition switch in position 1 6115900 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Gia12.00-16 Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-16 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTSIACTIONS \VE0028921 [2}Measure the voltage between the air condi- tioning clutch relay, socket C403, pin 1, circuit 15S-FA11 (GN/YE), wiring hamess side and ground. + Does the meter display battery voltage? Yes GO toca No LOCATE and RECTIFY the break in circuit 15S-FA11 (GN/YE) between the air condi- tioning clutch relay and soldered connection S110 using the Wiring Diagrams. CHECK the operation of the system. A (C9: CHECK THE AIR CONDITIONING CLUTCH CIRCUIT gt a \vFE0028026 ignition switch in position 0. [2 Use a fused test cable (10 A) to bridge the air conditioning clutch relay, socket C403, pin 3 and pin 5, wiring harness side + Does the air conditioning clutch work? Yes GO to C12 No GO to C10 CONDITIONING CLUTCH C10: CHECK FOR OPEN CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND AIR Li )pisconnect connector C401 from air condition- ing clutch, gS 8800en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX BACK TO CHAPTER INDEX Giai2.00-18 Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-18 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTSIACTIONS vFE0028922 [Switch on the blower. [Switch on the air-conditioning system. CAUTION: It is imperative that a test lamp with a nominal voltage of 12 V anda nominal power rating of 1.2 Wis used during the following test. Otherwise the powertrain control module (PCM) could be damaged, or the test could deliver incorrect results. 5 |Use a test lamp (12 V, 1.2 W) to check the voltage at the air conditioning clutch relay, socket C403, between pin 1 and pin 2, wiring harness side. + Does the test lamp illuminate? > Yes RENEW the air conditioning clutch relay. CHECK the operation of the system - All except vehicles with diesel engines: In addition, CHECK and if necessary RENEW the air conditioning clutch diode. CHECK the operation of the system. No - All except vehicles with diesel engines: GO to C13 - Vehicles with diesel engine: GO to C15 C13: CHECK THE AIC REQUEST SIGNAL AT THE PCM \vFE0028882 ignition switch in position 0. [2 Disconnect connector C343 from the PCM. [3 lignition switch in position I [4 Switch on the blower. [5 |Switch on the air-conditioning system. [A\caution: In order to avoid damaging the Vehicle, the measuring device should be operated in a measuring range up to a maximum of 200 mA. 6 |Measure the current between the PCM, con- nector C343, pin F22, circuit 31S-FA87 (BK/GN), wiring hamess side and battery volt- age. + Is a current of more than 8 mA measured? = Yes gS 8800en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 412.00-19 Climate Control System - General Information 412.0019 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTS/ACTIONS GO to C14 No GO to C17 C14: CHECK FOR OPEN CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND PCM ignition switch in position 0. leasure the resistance between the air condi- tioning clutch relay, socket C403, pin 2, circuit 918-FA11 (BK/YE), wiring harness side and the ooo PCM, connector C343, pin M26, circuit 918-FA11 (BK/YE), wiring hamess side. of——o0} ‘vE0026024 C15: CHECK THE A/C REQUEST SIGNAL AT TH! + Isa resistance of less than 2 Ohm registered? 3 Yes CHECK PCM with WDS. RENEW PCM if necessary. CHECK the operation of the system 4 No LOCATE and RECTIFY the break in circuit 91S-FA11 (BK/YE) between the air condi- tioning clutch relay and the PCM using the Wiring Diagrams. CHECK the operation of the system iE PCM \VFE0031499 6115900 en JAX caution: In order to avoid damaging the [em [i ignition switch in position 0. [2 Pisconnect connector C370 from the PCM, [3 lignition switch in position II itch on the blower. itch on the air-conditioning system. vehicle, the measuring device should be operated in a measuring range up toa maximum of 200 mA. leasure the current between the PCM, con- nector C370, pin A2, circuit 31S-FA87 (BK/GN), wiring harness side and battery voltage. tls a current of more than 8 mA measured? 11/2004 2005.25 Fiesta, DdBACK TO CHAPTER INDEX Gia12-00-20 Climate Control Syste FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX m - General Information 4412-00-20 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTSIACTIONS = Yes GO to C16 No GO to C17 16: CHECK FOR OPEN CIRCUIT BETWEEN Ali R CONDITIONING CLUTCH RELAY AND PCM vFE0028923 [1 lignition switch in position 0. [2 Disconnect connector C372 from the PCM. [3 Measure the resistance between the air condi- tioning clutch relay, socket C403, pin 2, circuit 91S-FA11 (BK/YE), wiring harness side and the PCM, connector C372, pin F4, circuit 91S-FA11 (BK/YE), wiring harness side. + Is a resistance of less than 2 Ohm registered? Yes CHECK PCM with WS RENEW PCM if necessary. CHECK the operation of the system No LOCATE and RECTIFY the break in circuit 91S-FA11 (BK/YE) between the air condi- tioning clutch relay and the PCM using the Wiring Diagrams. CHECK the operation of the system. C17: CHECK THE QUANTITY OF REFRIGERANT IN THE SYSTEM ignition switch in position 0. [2 |Check the quantity of refrigerant in the system REFER to Air Conditioning (A/C) System Re- covery, Evacuation and Charging in this section + Is the quantity of refrigerant in the system in accordance with the manufacturer's specifica- tions? = Yes Goto C18 No FILL the system with the correct quantity of refrigerant. REFER to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. CHECK the system function. C18: CHECK THE AC REQUEST SIGNAL AT THI iE REFRIGERANT HIGH-PRESSURE SWITCH Disconnect connector C405 from refrigerant gS 8800en \igh-pressure switch. 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX BACK TO CHAPTER INDEX Gia12.00-22 Climate Control System - General Information DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTSIACTIONS [2 Disconnect connector C402 from refrigerant low-pressure switch. 3 Ignition switch in position II [Switch on the blower. [Switch on the air-conditioning system. (AX caution: in order to avoid damaging the vehicle, the measuring device should be operated in a measuring range up to a maximum of 200 mA. 6 \vFE0028909 Measure the current between the refrigerant low-pressure switch, connector C402, pin 1, circuit 31S-FA17 (BK/RD), wiring harness side and battery voltage. + Is a current of more than 8 mA measured? 3 Yes GO to C21 No GO to C22 C21: CHECK REFRIGERANT LOW-PRESSURE SWITCH \vFE0028372 ignition switch in position 0. [2 |Measure the resistance at the refrigerant low-pressure switch, connector C402, between pin 7 and pin 4, component side +15 a resistance of less than 2 Ohm registered? Yes LOCATE and REPAIR the break in circuit 31S-FA1TA (BK/RD) between the refrigerant high-pressure switch and the refrigerant low-pressure switch using the Wiring Dia- grams.CHECK the operation of the system. No RENEW the refrigerant low-pressure switch gS 8800en CHECK the operation of the system. 11/2004 2005.25 Fiesta > FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-22 >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 412.00-28 Climate Control System - General Information 412.0023 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTS/ACTIONS C22: CHECK CIRCUIT BETWEEN AIR CONDITIONING CONTROL PANEL AND REFRIGERANT LOW-PRESSURE SWITCH FOR OPEN CIRCUIT 4 Jgnition switch in position 0. 2 Disconnect connector C302 from the air condi- tioning control pane. [3]Measure the resistance between the air condi- tioning control panel, connector C302, pin 2, circuit 31S-FA17 (BK/RD), wiring harness side and the refrigerant low-pressure switch, con- nector C402, pin 1, circuit 31S-FA17 (BK/RD), wiring harness side. \vFE0028807 + Isa resistance of less than 2 Ohm registered? Yes GO to C23 A >No a LOCATE and REPAIR the break in circuit 31S-FA17 (BKIRD) between the air condi- tioning control panel and the refrigerant low-pressure switch using the Wiring Dia- grams.CHECK the operation of the system. C23: CHECK THE VOLTAGE AT THE AIR CONDITIONING CONTROL PANEL TiMeasure the voltage between the air condi- tioning control panel, connector C302, pin 7, circuit 29-FA10 (OG/GN), wiring hamess side and ground. eles \vFE028905 + Does the meter display battery voltage? — Yes GO to C24 No LOCATE and RECTIFY the open circuit between the air conditioning control panel and fuse F4 using the Wiring Diagrams. CHECK the operation of the system. <— 375800 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Gia12-00-24 DIAGNOSIS AND TESTING (Continued) Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX > 4412-00-24 TEST CONDITIONS DETAILS/RESULTSIACTIONS ‘C24: CHECK THE VOLTAGE AT THE AIR CONDITIONING CONTROL PANEL \vFE0028895 7 [ignition switch in position I 2 IMeasure the voltage between the air condi- + Does the meter display battery voltage? Yes No tioning control panel, connector C302, pin 1, circuit 15-FA90 (GNIBK), and ground. wiring hamess side GO to C25 LOCATE and RECTIFY the open circuit between the air conditioning control panel and soldered connection $266 using the a Wiring Diagrams. CHECK the operation of the system. THE BLOWER SWITCH C25: CHECK FOR OPEN CIRCUIT BETWEEN THE AIR CONDITIONING CONTROL PANEL AND DO} les1566 ignition switch in position 0. [Set the blower switch to position 1. [3 Measure the resistance between the air condi- tioning control panel, connector C302, pin 5, circuit 31S-FA13 (BK/OG), wiring hamess side and ground. + Isa resistance of less than 2 Ohm registered? > Yes >No GO to C26 LOCATE and RECTIFY the break in circuit 318-FA13 (BK/OG) between the air condi- tioning control panel and the blower switch using the Wiring Diagrams. CHECK the operation of the system. gS 8800en 11/2004 2005.25 Fiesta >FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX BACK TO CHAPTER INDEX J 412.00-25 Climate Control System - General Information 412.0025 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTS/ACTIONS C26: CHECK THE GROUND CONNECTION OF THE AIR CONDITIONING CONTROL PANEL Tt IMeasure the resistance between the air condi- tioning control panel, connector C302, pin 10, circuit 31-LH27 (BK), wiring hamess side and Q ground \vFE0028896 +15 a resistance of less than 2 Ohm registered? Yes ‘CHECK and if necessary RENEW the air conditioning control panel. CHECK the operation of the system. No LOCATE and REPAIR the open circuit be- tween the air conditioning control panel and A ground connection G12 using the winng. | Diagrams. CHECK the operation of the sys- tem. PINPOINT TEST D: AIR CONDITIONING OPERATING CONTINUOUSLY TEST CONDITIONS DETAILSIRESUL TS/ACTIONS D1: CHECK AIR CONDITIONING CLUTCH RELAY EReniten ‘switch in position 0. jisconnect air conditioning clutch relay from socket C403 (relay box, engine compartment). ignition switch in position II un the engine at idle speed. heck operation of air conditioning clutch. + Does the air conditioning clutch work? 3 Yes GO to D2 No GO to D3 115900 en 11/2004 2005.25 Fiesta, Dd <BACK TO CHAPTER INDEX Gia12.00-26 DIAGNOSIS AND TESTING (Continued) Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-26 TEST CONDITIONS DETAILS/RESULTSIACTIONS CLUTCH FOR SHORT TO VOLTAGE D2: CHECK CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND AIR CONDITIONING \VFE0033613 [1 ]Measure the voltage between the air condi- tioning clutch relay, socket C403, pin 6, circuit 15S-FA1 (GN/BU) (vehicles with diesel engine 15S-FAG (GN/YE)), wiring hamess side and ground. +I. voltage measured? Yes LOCATE and REPAIR the short to battery voltage in the circuit between the air condi- tioning clutch relay and air conditioning clutch using the Wiring Diagrams. No INSTALL A NEW air conditioning clutch CHECK the operation of the system. D3: CHECK OPERATION OF AIR CONDITIONING CLUTCH RELAY ignition switch in position 0. [2 |Check the air conditioning clutch relay accord- ing to the component check at the end of this section. + Is the air conditioning clutch relay OK? Yes - All except vehicles with diesel engines: GO to D4 - Vehicles with diesel engine: GO to D6 >No RENEW the air conditioning clutch relay. CHECK the operation of the system. - All except vehicles with diesel engines: In addition, CHECK and if necessary RENEW the air conditioning clutch diode. CHECK the operation of the system. D4: CHECK THE A/C REQUEST SIGNAL AT THE POWERTRAIN CONTROL MODULE (PCM) [Disconnect connector C343 from the PCM. ignition switch in position I 3 |Switch on the blower. ‘4 [Switch off the air conditioning system. gS 8800en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX < 412-00-27 DIAGNOSIS AND TESTING (Continued) Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.0027 TEST CONDITIONS DETAILS/RESULTS/ACTIONS vFEDo2e892 [AX cauTion: in order to avoid damaging the vehicle, the measuring device should be operated in a measuring range up toa maximum of 200 mA. [5 Measure the current between the PCM, con- nector C343, pin F22, circuit 31S-FA87 (BKIGN), wiring harness side and battery volt- age. + Is a current of more than 8 mA measured? 3 Yes GO to D8 >No. GO to D5 GROUND D5: CHECK CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND PCM FOR SHORT TO \VFE0033614 1 }ignition switch in position 0. 2 Measure the resistance between the air condi- tioning clutch relay, socket C403, pin 2, circuit 91S-FA11 (BK/YE), wiring harness side and ground. + Is a resistance of more than 10,000 Ohm measured? Yes CHECK PCM with WDS. RENEW PCM if necessary. CHECK the operation of the system. No LOCATE and RECTIFY the short to ground in circuit 91S-FA11 (BKIYE) between the air conditioning clutch relay and the PCM using the Wiring Diagrams. CHECK the operation of the system D6: CHECK THE AIC REQUEST SIGNAL AT THE POWERTRAIN CONTROL MODULE (PCM) 7 Pisconnect connector C370 from the PCM nition switch in position I 6115900 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Giai2.00-28 DIAGNOSIS AND TESTING (Continued) Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-28 TEST CONDITIONS DETAILS/RESULTSIACTIONS \VFE0031499 [Switch on the blower. [Switch off the air conditioning system. CAUTION: In order to avoid damaging the vehicle, the measuring device should be operated in a measuring range up to a maximum of 200 mA. 5 |Measure the current between the PCM, con- nector C370, pin A2, circuit 31S-FA87 (BK/GN), wiring harness side and battery voltage. + Is a current of more than 8 mA measured? 3 Yes GO to D8 No GO to D7 D7: CHECK CIRCUIT BETWEEN AIR CONDITIONING CLUTCH RELAY AND PCM FOR SHORT TO A GROUND VFE0033614 ignition switch in position 0. [2 Disconnect connector C372 from the PCM. [3 |Measure the resistance between the air condi- tioning clutch relay, socket C403, pin 2, circuit 91S-FA11 (BK/YE), wiring hamess side and ground + Is a resistance of more than 10,000 Ohm measured? Yes CHECK PCM with WDS RENEW POM if necessary. CHECK the operation of the system. No LOCATE and RECTIFY the short to ground in circuit 91S-FA11 (BK/YE) between the air conditioning clutch relay and the PCM using the Wiring Diagrams. CHECK the operation of the system. gS 8800en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX Yes GO to D10 No 6115900 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Gia12-00-30 DIAGNOSIS AND TESTING (Continued) Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-30 TEST CONDITIONS DETAILS/RESULTS/ACTIONS TOCATE and REPAIR short to ground in circuit 31S-FA17 (BK/RD) between the air conditioning control panel and the refrigerant low-pressure switch using the Wiring Dia- grams. CHECK the operation of the system. D10: CHECK REFRIGERANT LOW-PRESSURE SWITCH VFE0033616 [1 |Measure the resistance between the refrigerant low-pressure switch, C402, pin 1, component side and ground. + Is a resistance of more than 10,000 Ohm measured? Yes GO to D11 No RENEW the refrigerant low-pressure switch CHECK the operation of the system. REFRIGERANT LOW-PRESSURE SWITCH FOR D11: CHECK CIRCUIT BETWEEN REFRIGERANT HIGH-PRESSURE SWITCH AND SHORT TO GROUND \vFE0033617 [Disconnect connector C405 from refrigerant high-pressure switch. 2 |Measure the resistance between refrigerant high-pressure switch, connector C405, pin 4, circuit 31S-FA17A (BK/RD), wiring harness side and ground, + Is a resistance of more than 10,000 Ohm measured? Yes GO to D12 >No gS 8800en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX < 412-00-31 DIAGNOSIS AND TESTING (Continued) Climate Control System - FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.0031. General Information TEST CONDITIONS DETAILS/RESULTS/AC TIONS LOCATE and REPAIR short to ground in Circuit 31S-FA17A (BKIRD) between the re- frigerant high-pressure switch and the re- frigerant low-pressure switch using the Wir- ing Diagrams. CHECK the operation of the system D12: CHECK CIRCUIT BETWEEN REFRIGERANT HIGH-PRESSURE SWITCH AND REFRIGERANT LOW-PRESSURE SWITCH FOR SHORT TO GROUND \vFEO033618 jeasure the resistance between refrigerant high-pressure switch, connector C405, pin 1, circuit 31S-FA87 (BK/GN), wiring hamess side and ground. +Is a resistance of more than 10,000 Ohm A measured? Yes RENEW the refrigerant high-pressure switch. CHECK the operation of the system. No LOCATE and RECTIFY the short to ground in circuit 31S-FA87 (BK/GN) between the refrigerant high-pressure switch and the PCM using the Wiring Diagrams. CHECK the operation of the system. PINPOINT TEST E: RECIRCULATED AIR FLAPS Ok) INOPERATIVE (AIR CONDITIONING FUNCTION TEST CONDITIONS DETAILS/RESULTS/ACTIONS E1: CHECK VOLTAGE AT RECIRCULATED AIR FLAP ACTUATOR nition switch in position 0. connect connector C611 from recirculated air flap actuator. [B}ignition switeh in position 1 6115900 en 11/2004 2005.25 Fiesta, DdBACK TO CHAPTER INDEX Gia12-00-32 Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-32 DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTSIACTIONS \vE0028920 [é]Measure the voltage at the recirculated air flap ‘actuator, connector C611, between pin 4, circuit 15S-FA76 (GN/RD) and pin 2, circuit 318-FA76 (BK/OG), wiring harness side. 5 [Actuate the recirculated air switch several times during the measurement. + Is a voltage of more than 10 V measured with alternating polarity? — Yes CHECK the mountings and the operation of the recirculated air flaps and recirculated air flap actuation cables. If the recirculated air flaps and the recirculated air flap actuation cables are OK, RENEW the recirculated air flap actuator. CHECK the operation of the system. No GO to E2 CONDITIONING CONTROL PANEL 2: CHECK FOR OPEN CIRCUIT BETWEEN RECIRCULATED AIR FLAP ACTUATOR AND AIR ignition switch in position 0. [2 JDisconnect connector C302 from the air condi- tioning control panel. 3 Measure the resistance between the air condi- tioning control panel, connector C302, pin 3, circuit 31S-FA76 (BK/OG), wiring hamess side and the recirculated air flap actuator, connector C611, pin 2, circuit 31S-FA76 (BK/OG), wiring harness side. \VFE0028698 + Is a resistance of less than 2 Ohm registered? > Yes GOto ES No gS 8800en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX DIAGNOSIS AND TESTING (Continued) TEST CONDITIONS DETAILS/RESULTSIAC TIONS [8 Measure the voltage between the air condi- tioning control panel, connector C302, pin 3, circuit 31S-FA76 (BK/OG), wiring hamess side and ground. \vFE0028900 + Is a voltage measured during any of these measurements? = Yes LOCATE and RECTIFY the short to voltage supply in the relevant circuit between the air conditioning control panel and the recircu- lated air flap actuator using the Wiring Dia- grams. CHECK the operation of the system. No A GO to ES E5: CHECK CIRCUITS BETWEEN RECIRCULATED AIR FLAP ACTUATOR AND AIR 4 CONDITIONING CONTROL PANEL FOR SHORT TO GROUND ignition switch in position 0. [2 ]Measure the resistance between the air condi- tioning control panel, connector C302, pin 4, circuit 15S-FA76 (GN/RD), wiring harness side and ground, \vFE0028002 gS 8800en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX BACK TO CHAPTER INDEX Gia12.00-36 DIAGNOSIS AND TESTING Component Tests Air conditioning clutch relay 1. Check the normally open contact in the unswitched state’ + Measure the resistance at the air conditioning clutch relay, between pin 3 and pin 5, component side. + Is a resistance of more than 10,000 Ohm measured? + Ifyes, go to 2 + Ifo, RENEW the air conditioning clutch relay. Climate Control System - General Information \vFE0O31236 FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.0036 2. Check the normally open contact in the ‘switched state: + Use a fused test cable (1 A) to connect pin 1 of the air conditioning clutch relay, component side, to the battery positive terminal + Use a test cable to connect pin 2 of the air conditioning clutch relay, component side, to the battery negative terminal. + Measure the resistance at the air conditioning clutch relay, between pin 3 and pin 5, component side. + Is a resistance of less than 2 Ohm registered? + Ifyes, then the air conditioning clutch relay is OK. + Ifno, RENEW the air conditioning clutch relay. gS 8800en \VFE0031237 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX BACK TO CHAPTER INDEX Giai2.00-38 Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX > 4412-00-38 GENERAL PROCEDURES General Equipment Refrigerant centre Refrigerant analyzer 1. NOTE: This step is not necessary for vehicles equipped with the 1.6L Duratorg-TDCi (DV) diesel engine. Remove the right-hand headlamp. For additional information, refer to Section 417-01.[Exterior Lighting, REMOVAL AND. INSTALLATION, Headlamp Assembly] 2, AXcauTion: The reigorant analyzer must be used before recovery, otherwise the refrigerant centre may become contaminated. Contaminated refrigerant must be disposed of as. hazardous waste. Always follow the manufacturer's instructions when using the refrigerant centre and the A refrigerant analyzer. NOTE: All vehicles except those with the 1.6L Duratorg-TOCi (DV) diesel engine Unscrew and remove the protective caps from the AIC charging connections. 1,Low-pressure connection 2,High-pressure connection eg S222844 en Conditioning (A/C) System Recovery, Evacuation and Charging (34 620 2) 3. Axcautoow: The refrigerant analyzer must be used before recovery, otherwise the refrigerant center may become contaminated. Contaminated refrigerant must be disposed of as hazardous waste. Always follow the manufacturer's instructions when using the refrigerant center and the refrigerant analyzer. NOTE: Vehicles with the 1.6L Duratorg-TDCi (DV) diesel engine Unscrew and remove the protective caps from the AIC charging connections. 1.Low-pressure connection 2. High-pressure connection [Es70s8 4, Pull back the catches of the quick-fit un- ions on the refrigerant centre lines. \VFE0031288 5. NOTE: Larger inner diameter for high-pressure side, Smaller inner diameter for low-pressure side Connect the refrigerant centre lines to the AVC charging connections. 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX Gi stz-00-39 GENERAL PROCEDURES (Continued) . Axwarnine: When recovering the refrigerant do not allow it to enter the atmosphere under any circumstances. Failure to follow these instructions may result in personal injury. NOTE: When removing components of the air conditioning system, calculate the residual quantity of refrigerant oil. For additional information, refer to Refrigerant Oil Adding in this section. Recover the refrigerant from the A/C system via the low-pressure connection in accordance with the refrigerant centre manufacturer's instructions. 7 AXcauTion: The AC system must be evacuated for about 30 minutes before recharging, to ensure that it operates correctly. Axcaution: If moisture was able to enter an ‘open system over an extended period (several hours), install a new A accumulator/dehydrator and increase the evacuation time to 2-3 hours. Evacuate the AIC system according to the refrigerant centre manufacturer's instructions. 8. NOTE: If an air conditioning system that was filled with refrigerant is being evacuated, some refrigerant will still be in the refrigerant oil in the compressor. This remaining refrigerant may evaporate, causing a slight increase in pressure during the leak test. The system is. leak-free provided, that this pressure increase does not exceed 20 mbar (2 kPa, 0.29 psi). Perform the leak test. 1.For the leak test, close the hand valves on the pressure gauge set, switch off the refrigerant centre vacuum pump and observe the low pressure gauge. 2. Locate any leaks in the A/C refrigerant circuit using a leak tester. For additional information, refer to Fluorescent Dye Leak Detection/ Electronic Leak Detection in this section. 9. Top up with refrigerant oil. For additional information, refer to Refrigerant Oil Adding in this section. < 6332844 en Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.0039 AXcaution: the air conditioning system must always be evacuated before charging. Failure to observe this instruction can cause damage to the AIC system. 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX > Gat2-00-40 Climate Control System - General Information 4412-00-40 GENERAL PROCEDURES (Continued) 10. NOTE: Depending on the type of refrigerant Install the right-hand headlamp. For centre and the equipment (with or without additional information, refer to Section heated filling cylinder), the air conditioning 417-01.[Exterior Lighting, REMOVAL AND system is either charged with liquid via the INSTALLATION, Headlamp Assembly] high-pressure connection or with gas through the low-pressure connection. NOTE: Charge quantity on sticker in engine compartment. Charging the AIC system (with liquid) via the high-pressure connection. 4. Open the shut-off valve on the high-pressure side 2.Switch the refrigerant centre to "Fill” mode and fill with the prescribed quantity of liquid refrigerant (R134a). 11. ZXcAUTION: Only gaseous charging of the air conditioning system is performed via the low-pressure connection. Failure to follow these instructions may cause damage to the compressor. Charging the AIC system via the low-pressure connection. A. 1.0pen the shut-of valve on the low-pressure A side 2. Switch the refrigerant centre to Fill” mode and charge with gaseous refrigerant. 3. Top up with the remaining amount of refrigerant whilst the air conditioning is switched on. For this purpose, run the engine at approx. 1200-1500 rpm. Switch the air conditioning to maximum cooling Power and fresh air mode. Set the blower to maximum speed. Fill with the remainder of the prescribed fill capacity. 12, AAAWARNING: Do not detach the high-pressure hose when the air conditioning is switched on. Failure to follow these instructions may result in personal injury. Disconnecting the refrigerant centre. 1.Close the shut-off valves. 2. Switch off the refrigerant centre. 3. Disconnect the service unit line from the AVC charging connection. 4. Attach the protective caps to the filing valves. 13. NOTE: This step is not necessary for vehicles ‘equipped with the 1.6L Duratorq-TDCi (DV) diesel engine G332844 en 11/2004 2005.25 Fiesta < >BACK TO CHAPTER INDEX GENERAL PROCEDURES Refrigerant Oil Adding (34 621 1) AXcaution: store the refrigerant oil ina closed, sealed container to prevent the ingress of moisture. NOTE: Collect the refrigerant oil in a clean measuring cylinder when replacing the AIC compressor, the suction accumulator or refrigerant lines. 1. NOTE: This step only needs to be carried out when removing the A/C compressor. Drain the refrigerant oil from the A/C compressor. + Rotate the compressor shaft at least 6 to 8 turns when draining the refrigerant oil 2. NOTE: This step only needs to be carried out when removing the suction accumulator. Drain the refrigerant oil from the suction accumulator. 3. NOTE: This step only needs to be carried out when removing refrigerant lines. Drain the refrigerant oil from the refrigerant es. 4, NOTE: If more than one air conditioning system ‘component is being renewed, the oil quantity to be added is the sum of each individual quantity. NOTE: In addition, add the same quantity of new refrigerant oil as was collected in the oil separator of the servicing unit when the air conditioning was drained Add the calculated quantity of new refrigerant oil. For additional information, see Specifications in this subsection, 621702 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Gha12-00-42 Climate Control System - General Information 412-0042 GENERAL PROCEDURES Distribution System Cleaning ‘General Equipment 9. To dry out the system, switch off the air conditioning system and ventilate the ‘Spray gun with hose vehicle for approx. 15 minutes. 10. Switch off the engine. Name Specification Only Focus to MY 2004.75 and Galaxy ‘Odour eliminating 11. Remove the blower motor. agent (240 mi) (TOX Only Ka, Fiesta 96 to MY 2002.25 and Puma Number 142040) 12. Remove the blower motor resistor ‘Allvehicles Only Fiesta from MY 2002.25, Focus C-Max and Focus from MY 2004.75 with pollen filter 1. AXwarnine: Avoid contact with eyes and "13. Remove the pollen fier skin; wear gloves and respiratory Only Fiesta from MY 2002.25, Focus C-Max and protection. Ensure that you perform Focus from MY 2004.75 without pollen filter this operation in a well ventilated room. 44, Remove the pollen filter housing cover. Keep all vehicle doors and windows ‘ll vehicle ‘open for the duration of the operation. MSS our Do not inhale vapors under any oe in ya (240 ml circumstances. Do not smoke and eliminating agent (240 ml). avoid open fire and unprotected light 16. Awaanine: The maximum pressure of sources. Avoid contact with eyes and 13.5 bar must not be exceeded. Failure A skin; wear gloves and respiratory to observe this instruction can lead to a protection. Ensure that you perform injuries. this operation in a well ventilated room. Keep all vehicle doors and windows open for the duration of the operation. Do not inhale vapors under any circumstances. Do not smoke and avoid open fire and unprotected light sources. Failure to observe this instruction can lead to injuries. NOTE: The odour eliminating agent can remove deposits in the heater housing but cannot prevent odours that are distributed by the ventilation system, for example those caused by damp carpets. Precisely locate the musty or damp odour. 2. Disconnect the low pressure switch connector. 3. Turn on the ignition. 4, Open all ventilation nozzles. 5. Set the temperature control to maximum heating power. 6. Set the blower motor control switch to the highest setting. 7. Set the air distribution control to the fresh air position. 8. Start the engine and let it warm up to operating temperature. .G21704 en < Use the tyre inflator to apply pressure of 5.5 to 10 bar (operating pressure) to the spray gun. 17. Insert the hose of the spray gun as far as possible into the opening created by removal of the above component and point it in the direction of the evaporator. 18. By moving the hose, spray the odour eliminating agent over the entire surface of the evaporator. 19. Spray all of the odour eliminating agent into the opening. + Allow the odour eliminating agent to take effect for 10 minutes. 20. Install the components in reverse order. ine, switch off the air vehicle for approx. 15 minutes. 22. Open all ventilation nozzles. 23. Set the temperature control to maximum heating power. 24. Set the blower motor control switch to the highest setting. 26. Set the air distribution control to the fresh air position. 26. Switch off the engine. 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 412-00-43 Climate Control System - General Information 412.00-43> GENERAL PROCEDURES (Continued) 27. Connect the low pressure switch connector. 28. Ventilate the vehicle with the doors open for another 30 minutes. G21704 en 11/2004 2005.25 Fiesta, <4 >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Gia12.00-44 Climate Control System - General Information 412.0044 GENERAL PROCEDURES Contaminated Refrigerant Handling (34 620 9) AXcaution: Any R134a or R12 refrigerant which is contaminated with unsuitable refrigerant should be extracted only by means of a suitable servicing unit designed for the purpose of collecting and storing contaminated refrigerant, so that the spread to other vehicles can be prevented. 1. Use refrigerant identification equipment to check that there is contaminated refrigerant in the air conditioning system. 2. Inform the customer about the additional cost to repairing the system caused by the contamination. 3. Extract the contaminated refrigerant. qgeee73en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM < TO MODEL INDEX 4412-00-45 Climate Control System - General Information 412-00-45> GENERAL PROCEDURES Spring Lock Coupling 1. NOTE: Select special tool to suit the line ciameter. Fit the special tool. + Fit the special tool so that the inner collar can be guided into the clamping spring 4, Connect the refrigerant line. * Check the clamping spring for damage + Carefully pull out any damaged clamping springs using a thin piece of wire and install new one, ELma402005 ELms402007 2. Press the special tool into the clamping spring. 5. NOTE: Clean the connections using refrigerant A oil and a lint-free cloth Press the indicator ring into the clamping spring. VFE0021643, 3. Disconnect the refrigerant line. + Discard the O-ring seals. iureonZi645) w VFEOO2 1644 18266 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Gia12.00-46 Climate Control System - General Information FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-00-46 GENERAL PROCEDURES (Continued) 6. NOTE: Install new refrigerant line O-ring seals. NOTE: Coat the refrigerant line O-ring seals in clean refrigerant oil prior to installation. Connect the refrigerant lines. + Check that the clamping spring engages correctly. au FEO? 1646 .G18266 en < 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM < A TO MODEL INDEX 4412-00-47 Climate Control System - General Information 412-00-47> GENERAL PROCEDURES Electronic Leak Detection (34 620 7) General Equipment Automatic Calibration Halogen Leak Detector Manifold Gauge Set Refrigerant Identifier Adwaenne: Good ventilation before leak detection is necessary in the area where it is to be performed. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. While leak detection air movement must be prevented. 1. AXcauTion: te refrigerant identification equipment must be used before the a manifold gauge set is installed, otherwise the manifold gauge may become contaminated. Contaminated refrigerant must be disposed of as special waste. The manufacturer's instructions must be followed when working with the service unit. NOTE: Both manifold gauges should indicate 4,1-5,5 bar at 24°C with the engine off. Attach the manifold gauge set to the service gauge port valves. 1.For the leak test, close the manual valves on the gauge set. 2.if little or no pressure is indicated, charge the system with approx. 300g of refrigerant. 2. Use R-134a Automatic Calibration Halogen Leak Detector to leak test the refrigerant system. Follow the instructions included with leak detector for handling and operation techniques. 3. Ifa leak is found, recover the A/C system. 18270 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Gia12-00-48 Climate Control System - General Information 412.0048 GENERAL PROCEDURES Fluorescent Dye Leak Detection General Equipment UV Spot Lamp Manifold Gauge Set Fluorescent Dye Injector NOTE: Vehicles built 07/1999 onwards have a fluorescent tracer dye tablet inserted into the air conditioning (A/C) system. If tracer dye is present, there is a green cross on the suction accumulator. NOTE: On vehicles built up to 07/1999 tracer dye must be added 1. Using the dye injector, add 7.4 ml of Fluorescent Tracer Dye. NOTE: Some vehicles may have signs of reftigerant oil atthe spring lock couplers. This may be caused from the assembly process which applies to the fittings before installation to aid in assembly. When a spring lock coupler is A suspected of leaking, always wipe the fitting clean a and verify the leak with R-134a Automatic Calibration Halogen Leak Detector. NOTE: The exact location of leaks can be pinpointed by the bright yellow - green glow of the tracer dye. Since more than one leak may exist, always inspect each component. 2. Check for leaks using a 120 Watt UV Spot Lamp. Always scan all components, fittings and lines of the A/C system. 3. After the leak is found and repaired, remove any traces of dye with a general purpose oil solvent. 4. Verify the repair by operating the system for some minutes and inspecting with the UV lamp again. .G18269 en 11/2004 2005.25 Fiesta < >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 412.00-49 Climate Control System - General Information 412.0049 GENERAL PROCEDURES Vacuum Leak Detection (34 620 3) 1. Drain the air conditioning (A/C) system. For additional information, refer to Air Conditioning (AIC) System Recovery, Evacuation and Charging in this section. <— (18275 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX S014 Air Distribution and Filtering 412.014 SECTION 412-01 Air Distribution and Filtering VEHICLE APPLICATION: 2005.25 Fiesta CONTENTS PAGE DESCRIPTION AND OPERATION Air Distribution. 7 oe 412-01-2 Pollen filter 412-01-2 DIAGNOSIS AND TESTING Air Distribution and Filtering 412-01-3, REMOVAL AND INSTALLATION Pollen Filter. (34 350 0) 412.01-4 11/2004 2005.25 Fiesta, < >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Giai2.01-2 Air Distribution and Filtering 2012 DESCRIPTION AND OPERATION Air Distribution Pollen filter \VFE0031347 The purpose of the pollen filter is to remove particles which are 0,003 mm or larger from the air taken in. If installed, itis located in the heat exchanger/evaporator housing. A Itis accessible from the left-hand footwell A The pollen filter must be renewed in accordance with the service intervals. G179066 en 11/2004 2005.25 Fiesta < >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 12.013 Air Distribution and Filtering 412.01. DIAGNOSIS AND TESTING Air Distribution and Filtering REFER to Section 412-00. <— (atten 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Giai2.01-4 Air Distribution and Filtering FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 42014 Be REMOVAL AND INSTALLATION Pollen Filter (34 350 0) Removal All vehicles 1. Detach the centre console side trim on the left-hand side. Left-hand drive vehicles 2. Detach the accelerator pedal with its bracket from the bulkhead and lay it to one A. side (veniete with petrol engine shown). All vehicles 3. Remove the pollen filter housing cover. .G98893 en < 4. Remove the pollen filter. vFE031347 Installation 1, Reinstall the components in reverse order. A 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So s2024 Heating and Ventilation 412.024 SECTION 412-02 Heating and Ventilation VEHICLE APPLICATION: 2005.25 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications. so so 412.022 DESCRIPTION AND OPERATION Heating and Ventilation 412-02-3 Heater core / evaporator housing 412-02-3 DIAGNOSIS AND TESTING Heating and Ventilation 412.026 REMOVAL AND INSTALLATION Blower Motor (343740) 412-02-7 Heater Core (343640) 412-02. Heater Core and Evaporator Core Housing 412-02-10 A DISASSEMBLY AND ASSEMBLY a Heater Core and Evaporator Core Housing. 412-02-22 11/2004 2005.25 Fiesta, <4 >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Giai2.02.2 Heating and Ventilation 412022 SPECIFICATIONS Torque Specifications — Description Nm Tift Toiin Bolts, reinforcing element 20 15 = Bolts, heater core / evaporator housing to rein- 5 - cry forcing element Nut, heater core / evaporator housing 1 = o ger en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX >BACK TO CHAPTER INDEX 4, Remove the defrost air duct (shown with- out the crash padding for clarity). FEC 2. Detach the central junction box from the bulkhead and lay it to one side (shown without the crash padding for clarity), ~ /1 Vax \vFE0026842 5. Disconnect the blower motor connector (LHD vehicle shown). 3. Unscrew and remove the bolt from the de- frost air duct (shown without the crash padding for clarity). 105773 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Giai2.02-8 Heating and Ventilation 412028 REMOVAL AND INSTALLATION (Continued) 7. Remove the air intake flap (shown with the heater housing removed for clarity). vrea02s828 | Installation 1, Reinstall the components in reverse order. G105773 en 11/2004 2005.25 Fiesta < >BACK TO CHAPTER INDEX BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Gia12.02-10 Heating and Ventilation 412.0210 REMOVAL AND INSTALLATION Heater Core and Evaporator Core Housing 7. Remove the retaining clips of the quick-release couplings on the refrigerant Remover, quick-release lines. coupling 4/2" (blue) 412-027 (34-001) Special Tool(s) Remover, quick-release coupling 5/8" (black) 412-081 (34-003) rE0026467 Removal 1. Drain the cooling system. For additional 8. Detach the left-hand refrigerant lino from information, refer to Section 303-03A/ the evaporator using the special tool. 303.038, + Discard the O-rings 2. Remove the right-hand headlamp. For Z A. © additional information, refer to Section xe a additional information, refer to Section 412-00. 4. Remove the crash padding. For additional information, refer to Section 501-12. 5. Remove the air cleaner. For additional information, refer to Section 303-12. 6. Detach the coolant hoses from the heater \vFE0028459 core. 9. Detach the right-hand refrigerant line from the evaporator using the special tool. + Discard the O-rings. (ALA veEo026456 —/ VFE0026458 gj 028200 en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Si at2-02-11 Heating and Ventilation 412.0211. REMOVAL AND INSTALLATION (Continued) 10. Unscrew and remove the nut from the 13. Remove the ground strap bolt in the heater core / evaporator housing. left-hand footwell. 14, Disconnect the connector of the generic electronic module (GEM). Qua KS 7] Tai \WA 4 Vl BI/ \WA \ \ \ YW WY \ \ \ \ \\ \\ ) We \ \7 \\)) \ Ne a |W Oo \ )) \ vrcoo2s60 / \ r ‘VFE0026463 ~ 12. Disconnect the left-hand connector of the fascia/crash padding wiring harness (the 45. Detach the GEM from the reinforcing footwell trim is shown removed for clar- element and lay it to one side. ity). BACK TO CHAPTER INDEX Gla12.02-12 Heating and Ventilation FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-02-12 REMOVAL AND INSTALLATION (Continued) 16. Unclip part of the right-hand footwell trim. 417. Disconnect the right-hand connector of (the footwell trim is shown removed for clarity). the fasciaicrash padding wiring harness 19. Detach the antenna cable from the right-hand lower clips on the reinforcing element. i NE Tr \_ \= vuccorsres \\ | 20. Detach the antenna cable from the central clips on the reinforcing element. ‘vFE0026466 \vuE0026725 418. Detach the antenna cable from the right-hand upper clip on the reinforcing element. 21. Disconnect the electrical connectors for the blower motor, blower motor resistor and air inlet flap actuator. \vue0026723 ry a .G98900 en < 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX So s1202-13 Heating and Ventilation FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.0213 REMOVAL AND INSTALLATION (Continued) 22. Disconnect the connector from the airbag module. + Unclip the wiring harness. \vFE0026467 23. Unscrew and remove the ground cable bolt from the airbag module. 24. Disconnect the electrical connector of the handbrake warning lamp switch. 25. Remove the bolts of the windshield air duct (left-hand side shown). | val AEN 27. Mark the position of the reinforcing ele- ment relative to the A-pillars (left-hand side shown). yy} fie \%9] || \ \ fH [o | |_—_— \ \ G98900 en <4 1112004 2006.25 FiestaBACK TO CHAPTER INDEX Glai2.02-14 Heating and Ventilation FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-02-14 REMOVAL AND INSTALLATION (Continued) 28. Remove the A-pillar outer trims (left-hand side shown). 31. Remove the upper bolts of the heater core J evaporator housing. LA WSS vreooe13 | | [I Yo So I/ f/ AO 4 | ff / H 28, Remove the caps (left side shown). 32, Remove the side bolts from the heater core / evaporator housing (left side shown). KAW UR A XS 30. Remove the reinforcing element side bolts. eal WISP > | JO vre0001208 I \vFE0031305 33. Remove the reinforcing element lower bolts. .G98900 en < + /|/ {6 ] / ff vawaees Gy 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX 36. Axwarninc: Before performing any work on the electrical booster heater, make certain that the surface of its heating element has cooled to ambient temperature. Failure to observe this instruction can lead to injury. Detach the electrical booster heater from the heater core / evaporator housing and lay it to one side. 35. Remove the reinforcing element. 1.Lift the reinforcing element. 2.Pull the reinforcing element rearwards 37. AXcAUTION: Make sure that the water 4 G98900 en vecoozea1s | drain tube is not damaged when laying down the housing. Remove the heater core / evaporator housing. Installation 1. AXcaumion: Ensure that the adjustment nut for the heater core / evaporator housing is freely accessible. Screw on the adjustment nut for the heater core / evaporator housing (the heater core / 11/2004 2005.25 Fiesta, DdBACK TO CHAPTER INDEX Giai2.02-6 Heating and Ventilation FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-02-16 REMOVAL AND INSTALLATION (Continued) evaporator housing seal is shown removed for clarity). 1. Tighten the adjustment nut to the stop, 2.Undo the adjustment nut one turn. SS AXcauTion: Ensure that the rubber ‘grommet for the wiring harness of the electrical additional heater is correctly located in the bulkhead. Attach the electrical additional heater to the heater core / evaporator housing. vFE0031748 \——__ Axcaution: Make certain that the rubber ‘grommet of the heater core evaporator housing water drain tube is correctly located in the vehicle floor. Install the heater core / evaporator hous- ing. .G98900 en < \vFE0031749 4. Install the reinforcing element. 1.Slide the reinforcing element forwards. 2. Lower the reinforcing element. (SG veeo0s1867 | rll 5. Align the reinforcing element to the A-pillars (left-hand side shown). U4) 11/2004 2005.25 FiestaBACK TO CHAPTER INDEX ia \VFE0026468 14. Install the bolts of the windshield air 17. Connect the airbag module connector. ducts (left-hand side shown). + Clip the wiring harness in place. vFE026467 gj 028200 en 11/2004 2005.25 Fiesta :BACK TO CHAPTER INDEX So s1202-19 Heating and Ventilation FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.0219 REMOVAL AND INSTALLATION (Continued) 18. Connect the electrical connectors for the blower motor, the blower motor resistor and the air inlet flap actuator. 19, Attach the antenna cable to the middle clips on the reinforcing element. \vuE0026725 20. Attach the antenna cable to the right-hand lower clips on the reinforcing element. 21. Attach the antenna cable to the right-hand upper clip on the reinforcing element. \vue0026723 22. Connect the right-hand connector of the fascialcrash padding wiring harness (ti footwell trim is shown removed for clar- ity). \vE026466 23. Clip the right-hand footwell trim in place. A Gry ® Teer \VFE0031869 G98900 en <4 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Giai2-02-20 Heating and Ventilation 412.0220 REMOVAL AND INSTALLATION (Continued) 24. Attach the GEM to the reinforcing ele- 27. Connect the left-hand connector of the ment. fascialcrash padding wiring harness (the footwell trim is shown removed for clar- ity). 28. Clip the left-hand footwell trim in place. 1) \\LWAL a, 7) | \\NME2'\ NAA / LQ \ASZ WT} BT I) \e VC I F {/ | eS V4 vre0026463 — \VFE0031870 / 26. Install the left-hand footwell ground cable bolt. 29. Install the nut on the heater core / ff KK evaporator housing. /}}) if/ // /}/ gj 028200 en 11/2004 2005.25 FiestaBACK TO CHAPTER INDEX REMOVAL AND INSTALLATION (Continued) 30. NOTE: Coat the refrigerant line O-rings with clean refrigerant oil before installation. Connect the right-hand refrigerant line to the evaporator. + Install new O-rings on the refrigerant lines. vFE0031871 — 31. NOTE: Coat the refrigerant line O-rings with clean refrigerant oil before installation. Connect the left-hand refrigerant line to the evaporator. + Install new O-rings on the reftigerant lines. \vFE0081872 —_ 32, Install the retaining clips on the quick-release couplings on the refrigerant lines. \vFE0026457 G98900 en 33. Attach the coolant hoses to the heater core. 34. Install the air cleaner. For additional information, refer to Section 303-12. 35. Install the fascia/crash padding. For additional information, refer to Section 501-12. 36. Fill the air conditioning system. For formation, refer to Section ight-hand headlamp. For 4 tion, refer to Section 38. Fill and bleed the cooling system. For additional information, refer to Section 303-03A / 303-038. 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Glai2.02-22 Heating and Ventilation 412.0222 DISASSEMBLY AND ASSEMBLY Heater Core and Evaporator Core Housing Disassembly 1. Remove the heater core / evaporator 5. Remove the heater core. housing. For additional information, refer to Heater Core and Evaporator Core Housing in this section. 2, Remove the bracket for the coolant pipes. \vFE00s1289 6. Detach the air inlet flap operating cables {right-hand side shown). AL & Remove the heater core evaporator housing gasket. 7. Remove the air inlet flaps with the fresh air ducting (right-hand side shown). \vFE0091300 028901 en 11/2004 2005.25 FiestaBACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 412-02-28 Heating and Ventilation 412.02.23> DISASSEMBLY AND ASSEMBLY (Continued) 8. Remove the blower motor. 11. Remove the pollen filter housing cover. 12, Remove the bolts of the heater core / evaporator lower housing. ‘vE0026835 10. Remove the air inlet flap actuator motor. + Unelip the operating cables. 13, Remove the heater core / evaporator lower housing. \vFE0026836 BACK TO CHAPTER INDEX Glai2.02-24 Heating and Ventilation FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-02-24 DISASSEMBLY AND ASSEMBLY (Continued) 14, Remove the upper bolts of the heater core J evaporator housing. 17. Separate the heater core / evaporator housing. \vFE0031290 15. Remove the front bolts of the heater core / aporator housing. \VFE0026838 16. Remove the rear bolts of the heater core / evaporator housing. .G98901 en < 18. Remove the evaporator. \VFE0Os1346 19. Remove the temperature flap and the air distribution flap. \VFE031299 Assembly 1, Assemble the components in the reverse order. 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So s12.03-4 Air Conditioning 412.031 SECTION 412-03 Air Conditioning VEHICLE APPLICATION: 2005.25 Fiesta CONTENTS PAGE SPECIFICATIONS Specifications... 412-03-2 DESCRIPTION AND OPERATION Air Conditioning 412-03-3 Overview. 412-03-3 DIAGNOSIS AND TESTING Air Conditioning 412-03-5 REMOVAL AND INSTALLATION Clutch and Clutch Field Coll (346280) 412.036 Evaporator Core. (346220) -412-03-8 Evaporator Core Orifice (346240) 412-03-11 Low-Pressure Cutoff Switch 346290) 412-03-14 A High-Pressure Cutoff Switch . . (346310) 412-03-15 Condenser Core. (346320) 412-03-16 Suction Accumulator (346300) —412-03-18 Air Conditioning (A/C) Compressor — 1.25L Duratec- 16V (Sigma)/1.3L (a 626 0) Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigmay/2.0L Duratec-HE (M4) 4412-03-20 11/2004 2005.25 Fiesta, <4 >BACK TO CHAPTER INDEX Giai2.03.2 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412-03-2 SPECIFICATIONS AIC compressor Type [AIC compressor (vehicles with 1.4L Duratorg-TDCi (DV) diesel engine) ‘SEV 12 (Sanden) AIC compressor (vehicles with 1.6L Duratorg-TOCi (DV) diesel engine) ‘SD7V16 (Sanden) [AIC compressor (vehicles with?. 25L Duratec-16V (Sigma)/1.3L Duratec-8V FVS 080 |(Rocam)/t 4L Duratec-16V (Sigma)/1.6L Duratec-16V/ (Sigma) petrol engine) [AIC compressor (vehicles with 2.0L Duratec-HE (Ml4) petrol engine) FS10 Evaporator core ori Colour/Type Evaporator core orifice Redifixed Evaporator core orifice (vehicles with 1.6L Duratorg- TDCi (DV) diesel engine)| Bluelfixed Evaporator core orifice (vehicles with automatic transmission) brown/variable Tightening torques. Description Nm Ib.ft Thin Bolt, refrigerant line to A/C compressor 20 16 - Bolt, AIC compressor 20 15 - Bolt, AIC compressor drive plate 3 10 - High-pressure cutoff switch g : 7 Low-pressure cutoff switch 25 23 Nut, refrigerant line to condenser 8 - 71 A Bolt, accumulator/dehydrator 8 - 71 Nut, accumulator refrigerant line to A/C compressor} 8 - 71 gS 8801 en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX 412.033 Air Conditioning FORD FIESTA ST150 2005.25 WRM. TO MODEL INDEX 412.03. DESCRIPTION AND OPERATION £38736, = _ 1.4L/1.6L Duratec 16V Item] Part [Description Number Item] Part |Description Number 3 Compressor 4 = [Heat exchanger housing 4 = |High pressure connection 2 - ‘Condenser 5 - ‘Dual pressure switch 6 Accumulator G207063 en 11/2004 2005.25 Fiesta, < >BACK TO CHAPTER INDEX Giai2.03-4 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412-03-4 DESCRIPTION AND OPERATION (Continued) Item] Part Description Number 7 = __ [Low pressure connection 8 - Evaporator outlet 9 - __ [Condenser outlet The location of the components varies slightly depending on the engine variant Vehicles with a petrol engine are equipped with a performance regulated scroll compressor. Vehicles with a diesel engine are equipped with a ‘wobble plate compressor. eg 8207083 en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.035 Air Conditioning 412.035 > DIAGNOSIS AND TESTING Air Conditioning REFER to Section 412-00. BACK TO CHAPTER INDEX Giai2.03-6 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.036 REMOVAL AND INSTALLATION Clutch and Clutch Field Coil (34 628 0) Removal All vehicles 1. Remove the auxiliary drive belt. For additional information, refer to Section 303-05.[Accessory Drive, REMOVAL AND INSTALLATION, Accessory Drive Belt - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning] For additional information, refer to Section 303-05.[Accessory Drive, REMOVAL AND INSTALLATION, Power Steering Pump Belt - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning] For additional information, refer to Section 303-05,[Accessory Drive, REMOVAL AND INSTALLATION, Accessory Drive Belt - 2.0L Duratec-HE (mi4)] 2. Detach the AIC compressor clutch con- nector. ego 0784 en Vehicles with 2.0L engine 3. Disconnect the pressure cutoff switch electrical connector. + Unclip the pressure cutoff switch wiring hamess and lay it to the side 4, Detach the A/C compressor from the en- gine block, lower it and secure it at the All vehicles NOTE: Mark the installation position of the A/C compressor clutch connector in relation to the compressor housing. 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX So 412.03-7 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.03.7> REMOVAL AND INSTALLATION (Continued) 5. Remove the AIC compressor driveplate (AIC compressor shown removed for clar- ity). ‘vFwss02052 6. NOTE: If necessary, remove a seized AIC compressor pulley using a suitable remover. Remove the AIC compressor pulley. + Remove the spacer washers. + Discard the pulley snap ring. 8. NOTE: Mark the installation position of the A/C compressor clutch connector in relation to the compressor housing Remove the solenoid coil. 7. Remove the solenoid coil snap ring. + Discard the solenoid coil snap ring \VFE0037235 <— (108784 en \vE0037236 Installation AxcauTion: do not skew the solenoid coi when installing in the A/C compressor. NOTE: Installation position of the A/C compressor clutch connector in relation to the compressor a housing NOTE: Install new snap rings on the A/C compressor pulley and the solenoid coil 1. To assemble, reverse the disassembly procedure. 2. Check the AIC clutch air gap. For addit information, refer to Section 412-00 {Climate Control System - General Information, GENERAL PROCEDURES, Air Conditioning (A/C) Clutch Air Gap Adjustment] nal 11/2004 2005.25 Fiesta, DdBACK TO CHAPTER INDEX Giai2.03-8 REMOVAL AND INSTALLATION Evaporator Core (34 622 0) Removal 1. Remove the heater core / evaporator housing. For additional information, refer to Section 412.024. 2, Remove the bracket for the coolant pipes. a 0” vFE0026822 Air Conditioning 3. Remove the heater core / evaporator housing gasket. da ‘vFE0630369 FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 5. Unclip the operating cable of the left-hand air inlet flap from the heater core / evapo- rator housing. 412-03-8 6. Detach the left-hand air inlet flap from the fresh air duct and lay it to one side. + Remove the fresh air duct. eg 8785 en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX Si 412.03-9 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.03. REMOVAL AND INSTALLATION (Continued) 8. Remove the bolts of the heater core / evaporator lower housing. 11. Remove the front bolts of the heater core / evaporator housing. \VFE0026895 ‘vE0026098 9, Remove the heater core / evaporator lower housing. 12, Remove the rear bolts of the heater core / evaporator housing. ‘vFE0026696 \vE026899 10. Remove the upper bolts of the heater core J evaporator housing. 13, Separate the heater core / evaporator housing. \VFE0031290 <— (108785 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Gia12.03-10 Air Conditioning 412.0310 REMOVAL AND INSTALLATION (Continued) 14. Remove the evaporator. Installation 1, Reinstall the components in reverse order. .G105785 en 11/2004 2005.25 Fiesta < >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 412-03-11 Air Conditioning 412.03-11> REMOVAL AND INSTALLATION Evaporator Core Orifice (34 624 0) Filtering, REMOVAL AND INSTALLATION, Air Cleaner - 2.0L Duratec-HE (MI4)] 3. Evacuate the air conditioning (A/C) system. Special Tool(s) For additional information, refer to Section Remover, quick-release 412-00 {Climate Control System - General coupling 4/2" (blue) Information, GENERAL PROCEDURES, Air 7 Conditioning (AIC) System Recovery, 412-027 (34-001) Evacuation and Charging] 4, Remove the retaining clip of the refrigerant line quick-release coupling. Remover/installer, Fixed Orifice 412-034 (34-004) Remover, Broken Orifice Z 412-036 (34-005) la oa Adapter for 412-034 412-034-01 ee = 028076 A “ A 5. Axcaurion: Close off the refrigerant line and the evaporator to prevent dirt Removal ingress. RHD vehicles Detach the refrigerant line from the 4. Unclip the condenser to evaporator line evaporator. from the side member. + Discard the O-rings. wo AW 412-027 \ ie LAE All vehicles 2. Remove the air cleaner housing. For additional information, refer to Section 303-12,[Intake Air Distribution and Filtering, REMOVAL AND INSTALLATION, Air Cleaner - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)] For additional information, refer to Section 303-12,[Intake Air Distribution and G105786 en 11/2004 2005.25 Fiesta, <4 >BACK TO CHAPTER INDEX Gla12.03-12 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-03-12 REMOVAL AND INSTALLATION (Continued) AX caution: close off the refrigerant line to prevent dirt ingress. Remove the refrigerant line with the fixed orifice tube. + Discard the O-rings. veeooze878 / Vehicles with manual transmission 7. Using the special tool, remove the fixed orifice tube. A + Hook the special tool into the fixed orifice tube, turn it clockwise and remove the fixed orifice tube. 412-034 | ii a eS vveve4t0034 eg 187868 en Vehicles with automatic transmission 8. Hook the special tool into the fixed orifice tube. 4.Insert the special tool with adapter into the fixed orifice tube. 2. By turning the adapter a quarter turn, hook it into the fixed orifice tube qu) = iA 412-034-071 ‘yiz0221204 9. Remove the fixed orifice tube. + Turn the special tool, holding the adapter at the same time. 7120221205 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX Si 412.03-13 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.03-131 REMOVAL AND INSTALLATION (Continued) Alll vehicles 10. NOTE: This step is only necessary if the fixed orifice tube is faulty. Using the special tools, remove the bro- ken fixed orifice tube, 412-034 412-035 vFv9s10034 Installation 1. NOTE: Install new refrigerant line O-rings. A NOTE: Coat the refrigerant line O-rings with clean refrigerant oil before installation. Install the components in the reverse order. <— (3108786 en 11/2004 2005.25 Fiesta, > >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX Glai2.03-14 Air Conditioning 412.0314 REMOVAL AND INSTALLATION Low-Pressure Cutoff Switch (34 629 0) Removal 1. Remove the right-hand headlamp. For Installation additional information, refer to Section 417-01.[Exterior Lighting, REMOVAL AND —_1. NOTE: Install new O-rings on the low pressure INSTALLATION, Headlamp Assembly] switch. 2. Disconnect the low pressure switch con- NOTE: Coat the low pressure switch O-rings with nector. clean refrigerant oil before installation. Reinstall the components in reverse order. \vFE0030372 A 3. AXwarNine: Make certain thatthe valve 4 of the low pressure switch is completely closed after removal of the low pressure switch, to prevent refrigerant from escaping. Failure to observe this instruction can lead to injury. Remove the low pressure switch. + Discard the O-rings. \VFE0030610 go 8788 en 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 412.03-15 Air Conditioning 412.03-15> REMOVAL AND INSTALLATION High-Pressure Cutoff Switch (34 631 0) Removal 1. Raise the vehicle. For additional Installation information, refer to Section 100-02. 2. Disconnect the high-pressure switch elec- + Nore: Install new O-rings on the high pressure trical connector. switch. NOTE: Coat the high pressure switch O-rings with clean refrigerant oil before installation. Reinstall the components in reverse order. 0031134 3, AXwarnina: Make certain that the valve A of the high pressure switch is a completely closed after removal of the high pressure switch, to prevent refrigerant from escaping. Failure to observe this instruction can lead to injury. Remove the high pressure switch. + Discard the O-rings. 0031136 <—(ot08789en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Giai2.03-16 REMOVAL AND INSTALLATION Condenser Core (34 632 0) Removal 1. Drain the air conditioning system. For additional information, refer to Section 412-00. 2. Raise the vehicle. For additional information, refer to Section 100-02. 3. Disconnect the radiator fan resistor con- nector. Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-03-16 5. Unclip the radiator fan from the left-hand clip. 1. Pull back the clip. 2.Press the radiator fan out of the clip. ct VIZ 6. Remove the radiator fan. 1.Pull back the clip. 2.Press the radiator fan out of the clip and remove it. \vFE0031663, go15720en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 2.03.47 Air Conditioning 412.0317 > REMOVAL AND INSTALLATION (Continued) 7. Remove the radiator bracket bolts (right-hand side shown). 10. AXcauTion: Do not damage the foam 1. Remove the security bolts, seals of the condenser. 2.Unscrew the bolts. Remove the condenser. 8. A\cauTion: close off the refrigerant . lines and the A/C condenser to prevent _ Installation dirt from entering. Detach the refrigerant lines from the condenser. A + Discard the O-rings. 1. AXcauTion: Do not damage the foam ‘seals of the condenser. NOTE: Install new O-rings on the refrigerant lines, NOTE: Coat ihe retigerant ine O-rings wth clean refrigerant oil before installation, Reinstall the components in reverse order. 9, Detach the radiator and condenser from the front panel. <— (3108790 en 11/2004 2005.25 Fiesta, >BACK TO CHAPTER INDEX Giai2.03-18 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 4412-03-18 REMOVAL AND INSTALLATION Suction Accumulator (34 630 0) 4, Remove the refrigerant line quick release Special Tool(s) coupling securing clips. ~~ Remover, quick-release KES. coupling 3/4" (white) ao — 412-069 (34-002) oo Removal 4. Remove the right-hand headlamp assembly. For additional information, refer to Section 417-01.[Exterior Lighting, REMOVAL AND INSTALLATION, Headlamp Assembly] 2. Drain the air conditioning system. For additional information, refer to Section 412-00,{Climate Control System - General Information, GENERAL PROCEDURES, Air Conditioning (A/C) System Recovery, Evacuation and Charging] A. s disconnect the low-pressure cutoff ewitch electrical connector. \vFE0028516 5. AXcaumion: close off the refrigerant lines and the suction accumulator to prevent contamination. Using the special tool, disconnect the upper refrigerant line from the suction accumulator. + Discard the O-ring seals. /\ 412.069 |, gS 8803 en 11/2004 2005.25 Fiesta > >BACK TO CHAPTER INDEX FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX So 412.03-19 Air Conditioning 412.0319 REMOVAL AND INSTALLATION (Continued) 6. AXcauTion: close off the refrigerant lines and the suction accumulator to prevent contamination, Using the special tool, disconnect the lower refrigerant line from the suction accumulator. + Unelip the refrigerant line. + Discard the O-ring seals, ‘vF0028517 A 7. Raise and support the vehicle. a 8, Remove the suction accumulator. Wi YY / | fer Zoi) sale “Ss feat VFE00s1348 i Installation 1, NOTE: Install new refrigerant line O-ring seals, NOTE: Lubricate the refrigerant line O-ring seals with clean refrigerant oil before installation To install reverse the removal procedure. 6115903 en 11/2004 2005.25 Fiesta, < >BACK TO CHAPTER INDEX Gia12.03-20 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX > 4412-03-20 REMOVAL AND INSTALLATION Air Conditioning (A/C) Compressor — 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/2.0L Duratec-HE (MIA) (34 626 0) Removal All vehicles 1. Drain the AIC system. For additional information, refer to Section 412-00.{Climate Control System - General Information, GENERAL PROCEDURES, Air Conditioning (A/C) System Recovery, Evacuation and Charging] 2. Remove the accessory drive belt. For additional information, refer to Section 303-05.[Accessory Drive, REMOVAL AND INSTALLATION, Accessory Drive Belt - 1.4L Duratec-18V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning] For additional information, refer to Section 303-05.[Accessory Drive, REMOVAL AND INSTALLATION, Accessory Drive Belt - 2.0L Duratec-HE (MI4)] 3. Disconnect the AIC clutch connector (1.31 AL © engine shown). ego 8804 en 4. AXcauTion: Close off the refrigerant lines and the A/C compressor to prevent contamination. NOTE: On vehicles with a 2.0L engine, this step should only be carried out once the A/C compressor has been detached. Disconnect the refrigerant lines from the AIC compressor (1.31 engine shown). + Discard the O-ring seals. Vehicles with 2.0L engine 5. Disconnect the high-pressure cutoff switch electrical connector. + Unclip the high-pressure cutoff switch wiring harness and position it to one side. 11/2004 2005.25 Fiesta >BACK TO CHAPTER INDEX So 412-03-21 Air Conditioning FORD FIESTA ST150 2005.25 WRM TO MODEL INDEX 412.03.21> REMOVAL AND INSTALLATION (Continued) 6. Detach the AIC compressor from the en- gine, lower it and secure it to one side. Vehicles with 1.251,1.41 or 1.61 engine 7. AXcauTion: Support the AIC compressor before removing the retaining bolts and secure it to one side to prevent load being placed on the re lines. Remove the AIC compressor. <— 3715804 en Vehicles with 1.31 engine 2. AXcauTion: support the AIC compressor before removing the retaining bolts and secure it to one side to prevent load being placed on the refrigerant lines. Remove the AIC compressor. Installation 4. NOTE: Install new refrigerant line O-ring seals. 4 NOTE: Lubricate the refrigerant line O-ring seals with clean refrigerant oil before installation To install, reverse the removal procedure. 11/2004 2005.25 Fiesta, >