background image

  

Check for manifold vacuum at the open port on the vacuum check valve.  

Is manifold vacuum present at the open port on the vacuum check valve?

 

 

H4 CHECK THE VACUUM CHECK VALVE

 

Ignition OFF.  

Connect the vacuum pump to the open ports on the vacuum check valve and attempt to pull a vacuum.  
 

  

Can a vacuum be pulled on the vacuum check valve?

 

Yes

 

GO to 

H5

.  

 

No

 

INSTALL a new vacuum check valve 
(19A563). TEST the system for normal 
operation.

 

H5 CHECK THE VACUUM RESERVOIR LINE FOR BLOCKAGE

 

Disconnect the vacuum reservoir line at the vacuum reservoir.  

Connect the vacuum pump to the vacuum reservoir line at the vacuum check valve connection and attempt to pull a vacuum.  
 

  

Can a vacuum be pulled on the vacuum reservoir line?

 

Yes

 

REPAIR or INSTALL a new vacuum 
reservoir line. TEST the system for normal 
operation.  
 

No

 

GO to 

H6

.

 

H6 CHECK THE VACUUM RESERVOIR LINE FOR LEAKS

 

Plug the vacuum reservoir line at the vacuum reservoir connection.  

Leak test the vacuum reservoir line using the vacuum pump.  
 

  

Does the vacuum reservoir line leak?

 

Yes

 

REPAIR or INSTALL a new vacuum 
reservoir line. TEST the system for normal 
operation.  
 

No

 

GO to 

H7

.

 

H7 CHECK THE VACUUM RESERVOIR FOR A LEAK

 

Connect the vacuum pump reservoir line to the vacuum reservoir.  

With the vacuum pump connected to the vacuum reservoir line, leak test the vacuum reservoir.  
 

  

Does the vacuum reservoir leak?

 

Yes

 

INSTALL a new vacuum reservoir 
(19A566). TEST the system for normal 
operation.  
 

No

 

GO to 

H8

.

 

H8 CHECK THE FUNCTION SELECTOR SWITCH VACUUM SOURCE LINE FOR BLOCKAGE

 

Disconnect the function selector switch vacuum connector.  

Connect the vacuum pump to the function selector switch vacuum source line and attempt to pull a vacuum.  

Yes

 

REPAIR or INSTALL a new function 

Page 21 of 47

2003 Taurus/Sable Workshop Manual

11/22/2011

http://www.fordtechservice.dealerconnection.com/pubs/content/~WS3H/~MUS~LEN/19/...

Summary of Contents for 2003 Taurus

Page 1: ...equivalent scan tool Rotunda 73 III Automotive Meter 105 R0057 or equivalent R134a Manifold Gauge Set 176 R032A or equivalent Vacuum Pump Kit 416 D002 D95L 7559 A or equivalent Connector Refrigerant...

Page 2: ...llen filter optional 13 18A318 Vacuum control motor air inlet doors 14 Recirculation air inlet 15 19805 Blower motor 16 19860 Evaporator core 17 Temperature blend door full heat position 18 18476 Heat...

Page 3: ...Color Function Function Selector Switch Position MAX A C A C PANEL OFF PNL FLR FLR FLR DEF DEF 1 White Outside recircu lated air V NV NV V NV NV NV NV 2 Red Full floor NV NV NV V NV V NV NV 3 Black So...

Page 4: ...n air inlet 15 19805 Blower motor 16 19860 Evaporator core 17 Temperature blend door full heat position 18 18476 Heater core 19 A C evaporator case damper door full heat position 20 Panel floor door f...

Page 5: ...retrieved go to the SYMPTOM CHART to continue the diagnostics 9 If the RCC module cannot be accessed by the scan tool go to Pinpoint Test I Remote Climate Control Module Self Test The remote climate c...

Page 6: ...adings by 5 to obtain the Average Center Vent Temperature DTC Description Action P1436 A C Evaporator Air Temperature Sensor Circuit Low REFER to the Powertrain Control Emissions Diagnosis PC ED manua...

Page 7: ...inding stuck Vacuum line kinked pinched Vacuum control motor A C vacuum check valve 19A563 A C vacuum reservoir tank 19A566 Vacuum control motor actuator arm not connected to the door lever GO to Pinp...

Page 8: ...ntrol module REPAIR circuit 385 WH RD or circuit 729 RD WH for an open If okay INSTALL a new remote climate control module The temperature display will not switch between Celsius and Fahrenheit EATC I...

Page 9: ...end Door Actuator C289 Measure the resistance between RCC module C228 pin 21 circuit 249 DB LG and ground Measure the resistance between RCC module C228 pin 22 circuit 250 OG and ground Are the resist...

Page 10: ...sistance between RCC module C228 pin 5 circuit 436 RD LG and the temperature blend door actuator C289 pin 6 circuit 436 RD LG Measure the resistance between RCC module C228 pin 20 circuit 438 RD WH an...

Page 11: ...E LG Is the resistance greater than 10 000 ohms Yes INSTALL a new temperature blend door actuator 19E616 REFER to Section 412 04 TEST the system for normal operation No REPAIR circuits 438 RD WH and c...

Page 12: ...mal operation No INSPECT for a broken door or linkage If no condition is found INSTALL a new RCC module REFER to Section 412 04 TEST the system for normal operation Test Step Result Action to Take B1...

Page 13: ...normal operation No REPAIR circuit 470 PK BK for an open TEST the system for normal operation B5 CHECK CIRCUIT 790 WH OG FOR A SHORT TO CIRCUIT 470 PK BK Ignition OFF Disconnect RCC Module C228 Measur...

Page 14: ...DTC 1257 GO to C5 C3 CHECK CIRCUIT 788 RD OG FOR AN OPEN Ignition OFF Disconnect RCC Module C228 Measure the resistance between the RCC module C228 pin 7 circuit 788 RD OG and the ambient temperature...

Page 15: ...stance greater than 0 ohms Yes GO to D2 No INSTALL a new solar radiation sensor and bracket TEST the system for normal operation D2 CHECK THE REMOTE CLIMATE CONTROL MODULE OUTPUT VOLTAGE Ignition ON P...

Page 16: ...it 468 BN for a short to circuit 398 BK YE TEST the system for normal operation D6 CHECK CIRCUIT 468 BN FOR A SHORT TO GROUND Measure the resistance between the solar radiation sensor C287 pin 1 circu...

Page 17: ...n 5 ohms Yes GO to E4 No REPAIR circuit 833 TN CLEAR the DTCs REPEAT the self test E4 CHECK CIRCUIT 832 LB PK FOR SHORT TO GROUND Measure the resistance between the ICP C2009 pin 13 circuit 832 LB PK...

Page 18: ...Ignition OFF Disconnect Remote Climate Control Module C228 Measure the resistance between the remote climate control RCC module C228 pin 8 circuit 570 BK WH and ground Is the resistance less than 5 oh...

Page 19: ...f the blower motor is inoperative GO to Pinpoint Test O If the blower motor operates continuously in high speed GO to Pinpoint Test R If the blower motor is inoperative only in some speeds GO to Pinpo...

Page 20: ...l operation Test Step Result Action to Take H1 CHECK THE AIR FLOW IN EACH SETTING Ignition ON With the engine running set the blower motor speed to maximum Check the air flow in each function selector...

Page 21: ...HE VACUUM RESERVOIR LINE FOR LEAKS Plug the vacuum reservoir line at the vacuum reservoir connection Leak test the vacuum reservoir line using the vacuum pump Does the vacuum reservoir line leak Yes R...

Page 22: ...and try to pull a vacuum in each function selector switch position If the vacuum pump can pull and hold a vacuum the switch is plugged If the vacuum pump pulls a vacuum that slowly decays the hose is...

Page 23: ...NSTALLATION Check the attachment of the vacuum control motor arm to the damper door Is the vacuum control motor arm attached to the door or door crank arm Yes REPAIR the damper door TEST the system fo...

Page 24: ...alve Yes GO to I5 No INSTALL a new vacuum check valve TEST the system for normal operation I5 CHECK THE VACUUM RESERVOIR LINE FOR BLOCKAGE Disconnect the vacuum reservoir line at the vacuum reservoir...

Page 25: ...dule vacuum source line at the EATC module connection Leak test the EATC module vacuum source line using the vacuum pump Does the EATC module vacuum source line leak Yes REPAIR or INSTALL a new EATC m...

Page 26: ...OTOR LINE FOR BLOCKAGE Ignition OFF Disconnect the air inlet door vacuum control motor vacuum connector Disconnect the EATC module vacuum connector and attempt to pull a vacuum on the RECIRC vacuum co...

Page 27: ...se serious burns if the system is working correctly Allow the engine to reach normal operating temperature Feel the heater core inlet hose Is the heater core inlet hose too hot to handle Yes GO to J4...

Page 28: ...following diagnostic mode on the scan tool PCM PID WAC Does the PCM PID WAC read ON Yes REFER to the Powertrain Control Emissions Diagnosis PC ED manual No GO to K5 K5 CHECK THE PID ACCS WITH THE A C...

Page 29: ...een the RCC C228 pin 13 circuit 348 VT and the low charge switch C130 pin 1 circuit 348 VT Is the resistance less than 5 ohms Yes INSTALL a new RCC module REFER to Section 412 04 TEST the system for n...

Page 30: ...voltage between the A C compressor clutch field coil C100 circuit 347 BK YE and ground Is the voltage greater than 10 volts Yes GO to K17 No GO to K18 K17 CHECK THE GROUND AT THE A C COMPRESSOR CLUTC...

Page 31: ...o INSTALL a new A C compressor clutch field coil REFER to Section 412 03 TEST the system for normal operation K21 CHECK THE WAC OUTPUT FROM THE PCM Ignition ON With the engine running measure the resi...

Page 32: ...ion Selector Switch C294b or RCC module C228 Ignition ON Measure the voltage between the low charge switch C130 pin 1 circuit 348 VT and ground Is the voltage greater than 10 volts Yes REPAIR circuit...

Page 33: ...SOR CLUTCH AIR GAP Ignition OFF Measure the A C compressor clutch air gap at three equally spaced locations between the clutch hub and the A C compressor clutch pulley Is the A C compressor clutch air...

Page 34: ...438 RD WH Is the resistance less than 5 ohms Yes REPAIR circuits 436 RD LG and 438 RD WH for a short together TEST the system for normal operation No INSTALL a new temperature control potentiometer RE...

Page 35: ...m for normal operation No INSTALL a new temperature control potentiometer REFER to Section 412 04 TEST the system for normal operation M9 CHECK CIRCUITS 436 RD LG AND 437 YE LG FOR A SHORT TO GROUND D...

Page 36: ...e system for normal operation N2 CHECK FOR VOLTAGE TO THE BLOWER MOTOR Ignition ON Place the function selector switch in the floor position Measure the voltage between the blower motor C2004 circuit 3...

Page 37: ...operation N7 CHECK CIRCUIT 57 BK Measure the resistance between the function selector switch C294b pin 3 circuit 57 BK and ground Is the resistance less than 5 ohms Yes INSTALL a new function selector...

Page 38: ...Measure the voltage between the blower motor relay socket pin 87 and ground Is the voltage greater than 10 volts Yes GO to O3 No REPAIR the affected circuit TEST the system for normal operation O3 CH...

Page 39: ...ion O7 BYPASS THE BLOWER MOTOR RELAY Ignition OFF Disconnect Blower Motor Speed Control C271b Ignition ON Connect a fused 40A 12 gauge jumper lead between the blower motor speed control C271a pin 1 ci...

Page 40: ...71b Connect Blower Motor Speed Control C271a Ignition ON Press the MAX A C manual override button and adjust the blower speed to maximum Measure the voltage between the blower motor speed control C271...

Page 41: ...293 pin 3 circuit 57 BK pin 3 circuit 57 BK pin 4 circuit 261 OG BK pin 2 circuit 261 OG BK pin 1 circuit 754 LG WH pin 1 circuit 754 LG WH pin 2 circuit 752 YE RD pin 4 circuit 752 YE RD Yes GO to P3...

Page 42: ...ALL a new blower motor switch 18578 TEST the system for normal operation Test Step Result Action to Take R1 CHECK BLOWER OPERATION Ignition ON Press the override button for MAX A C operation and rotat...

Page 43: ...ance less than 5 ohms Yes INSTALL a new RCC module TEST the system for normal operation No REPAIR circuit 776 OG BK for an open TEST the system for normal operation Test Step Result Action to Take S1...

Page 44: ...ction to Take U1 CHECK THE BLOWER OPERATION Ignition ON Press the MAX A C button and rotate the blower motor speed control to HI Does the blower speed increase as you rotate the blower motor speed ove...

Page 45: ...damage the heater core Check the integrity of the heater water hose clamps Heater Core Plugged Did the voltage continually decrease without discontinuities U3 CHECK CIRCUIT 776 OG BK FOR A SHORT TO G...

Page 46: ...If the heater water hoses do not leak remove the heater core from the vehicle and carry out the bench test Heater Core Bench Test 1 Remove the heater core from the vehicle Refer to Section 412 02 2 Dr...

Page 47: ...n for an additional 30 minutes to remove any remaining refrigerant from the oil in the evaporator core or condenser core Then recheck for loss of vacuum If a very small leak is suspected allow the sys...

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