412-01 Ar-condicionado e ventilação

412-01-1 Climate Control 412-01-1 . SECTION 412-01 Climate Control VEHICLE APPLICATION: 2011.50 Ranger CONTENTS DESCRIPTION AND OPERATION Air Distribution and Filtering............................................................................................... Heating and Ventilation....................................................................................................... Air Conditioning.................................................................................................................. Control Components........................................................................................................... REMOVAL AND INSTALLATION Air Conditioning (A/C) Compressor – 2.5L Duratec-HE (122kW/165PS) - MI4................................................................................................................ Air Conditioning (A/C) Compressor – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma................................................................................ Air Conditioning (A/C) Compressor – 3.2L Duratorq-TDCi (148kW/200PS) - Puma.......................................................................................................... Air Conditioning (A/C) Pressure Sensor............................................................................. Condenser – 2.5L Duratec-HE (122kW/165PS) - MI4...................................................... Condenser – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma.................................................................................................... Receiver Drier..................................................................................................................... Blower Motor – LHD 4WD/LHD RWD........................................................... Blower Motor – RHD 4WD/RHD RWD.......................................................... Blower Motor Resistor.................................................................................... Climate Control Module...................................................................................................... Pollen Filter......................................................................................................................... Sunload Sensor.............................................................................................. Heater Core and Evaporator Core Housing....................................................................... Evaporator.......................................................................................................................... Ambient Air Temperature Sensor................................................................... PAGE 412-01-2 412-01-3 412-01-6 412-01-9 (34 626 4) 412-01-13 (34 626 4) 412-01-14 (34 626 4) 412-01-15 412-01-16 412-01-17 412-01-19 412-01-21 (34 374 0) 412-01-22 (34 374 0) 412-01-23 (34 382 0) 412-01-24 412-01-25 412-01-26 (34 665 0) 412-01-27 412-01-28 412-01-31 (34 676 0) 412-01-33

412-01-2 Climate Control 412-01-2 DESCRIPTION AND OPERATION Air Distribution and Filtering E129565 Air distribution, instrument cluster 1 3 6 5 4 5 E129564 Item Description 1 Air passages - side window defroster vents 2 Air passages œ defroster vents 3 Air passages - side vents (adjustable) 4 Air ducts, front footwell 5 Center duct vent 6 Air Duct - Navigation Display (if fitted) The fresh air flowing into the vehicle through the air inlet housing passes through a pollen filter which is located on the left-hand side of the climate control housing (LHD and RHD) and removes pollen and dust particles measuring 0.003 mm or more. The pollen filter must be changed at intervals in accordance with the service schedule. A special production pollen filter is installed in the factory and this must be cut off when the filter is changed. The service pollen filter is flexible and can be pushed together during installation or removal. 2 1 3 4

412-01-3 Climate Control 412-01-3 DESCRIPTION AND OPERATION Heating and Ventilation Overview of the climate control housing 3 4 8 10 E137637 Item Description 1 Pollen filter 2 Air inlet flap 3 Air Center vent 4 Air Defroster vent 5 Blower motor 6 Evaporator case 7 side foot well 8 Rear foot well Air flip door 10 Heat exchanger 2 1 6 5 7 Air flow - defroster vent-Warm air E137633

412-01-4 Climate Control 412-01-4 DESCRIPTION AND OPERATION Air flow - defroster vent-Cold air E137632 Air flow - center vent-warm air E137631 Air flow - center vent-Cold air E137634 Air flow - foot well-Warm air E137635

412-01-5 Climate Control 412-01-5 DESCRIPTION AND OPERATION Air flow - foot well-Cold air E137636

412-01-6 Climate Control 412-01-6 DESCRIPTION AND OPERATION Air Conditioning The air conditioning system is controlled by an thermostatic expansion valve. R134a refrigerant is used. Two options are available: ‡ Manual climate control ‡ Air conditioning system with automatic temperature control (DEATC) In order to prevent icing of the evaporator, the vehicles are equipped with a temperature sensor on the evaporator. The sensor measures the surface temperature of the cooling fins on the evaporator. If the measured temperature drops 2 1 6 7 E84427 Item Description 1 Condenser 2 A/C compressor 3 Blower motor 4 Evaporator 5 Expansion valve 6 Refrigerant drier 7 Cooling fan below a temperature of approx. +2 °C then the compressor clutch is deactivated. If the temperature increases above +4 °C the compressor is switched back on again. On systems with manual temperature control, the sensor signal is sent via the body control module (BCM) and the CAN bus to the powertrain control module (PCM), which then switches the compressor clutch on and off. On systems with automatic temperature control (DEATC) the sensor signal is first sent to the air conditioning module and then via the CAN bus to the PCM, which then switches the compressor clutch on and off. 3 4 5 8 10 11 Item Description 8 High pressure (gaseous and hot) High - pressure (liquid and warm) 10 Low - pressure (liquid and cool) 11 Low-pressure (gaseous and cool) Function The refrigerant compressor (2) which is driven by the engine sucks in the gaseous refrigerant from the evaporator (5) and compresses it. The

412-01-7 Climate Control 412-01-7 DESCRIPTION AND OPERATION temperature of the refrigerant rises to a value between 70 °C and 110 °C. It passes to the condenser (1) under high pressure. At this point heat is drawn from the refrigerant by the air being forced past the cooling fins. Because of this heat loss, the refrigerant liquefies and leaves the condenser. The refrigerant then passes under high pressure to the refrigerant drier (8). This serves as a storage medium and filters out any moisture contained in the refrigerant. The expansion valve (6) regulates the quantity of refrigerant injected into the evaporator (5) as a function of the pressure and temperature in the evaporator. The liquid refrigerant is vaporized in the evaporator. This causes heat to be extracted from the air coming into the vehicle. The air 1 10 8 E129654 Item Description 1 Heater core 2 Evaporator 3 Expansion valve 4 A/C lines 5 A/C compressor 6 Condenser therefore cools down and the moisture it contained is given up at the evaporator core. The gaseous flow of refrigerant which comes out from the evaporator at low pressure enters the expansion valve at the upper opening, from where it is sucked in by the refrigerant compressor. The A/C pressure converter sensor sends an analog signal to the PCM. After evaluating the different input signals, the PCM sends a control signal to the A/C clutch relay, which engages and disengages the compressor clutch. The PCM input signals come from the blower motor switch via the evaporator temperature sensor (vehicles with manual temperature control), via the A/C module (vehicles with automatic temperature control), the A/C pressure converter sensor and the PCM. 2 3 4 5 6 7 Item Description 7 Refrigerant drier 8 Coolant Pump Heater lines

412-01-8 Climate Control 412-01-8 DESCRIPTION AND OPERATION Electronic refrigerant compressor control valve E129655 A refrigerant compressor with electronic control valve is used. The control valve regulates the delivery rate of the refrigerant compressor according to the request received from the A/C module.

412-01- Climate Control 412-01- DESCRIPTION AND OPERATION Control Components Control assembly, climate control - vehicles with manual temperature control E140024 In vehicles with manual temperature control, the heating and A/C (air conditioning) are operated using three rotary switches. The air distribution flap and the temperature control flap are electrically actuated and controlled via potentiometer switches on the control head. In addition, the operating switch for recirculated air, heated front screen, heated rear screen and the on/off switch for the air conditioning are located on the control assembly. Vehicles with manual temperature control have a control assembly with the following functions: Button operated functions include: ‡ Switching the air conditioning system on and off ‡ Switching the windshield defrost function on and off ‡ Recirculated air control ‡ Switching the heated rear screen on and off Dial adjustments include: ‡ Temperature adjustment ‡ Air distribution ‡ Blower Control ‡ A/C max (used to cool the interior quickly) Control assembly, climate control - vehicles with automatic temperature control E140024 Vehicles with automatic temperature control have a control assembly with the following functions: Button operated functions include: ‡ Switching the air conditioning system on and off ‡ Air distribution ‡ Switching the max defrost function on and off ‡ Switching automatic climate control on and off ‡ Recirculated air control ‡ Switching the front and rear demist function on and off Dial adjustments include: ‡ Dual zone or mono zone temperature adjustment (between driver and passenger side) ‡ Switching the automatic climate control on and off ‡ Blower control

412-01-10 Climate Control 412-01-10 DESCRIPTION AND OPERATION Overview of the climate control housing - vehicles with manual temperature control 4 E140029 Item Description 1 Actuator - temperature flap 2 Lever - temperature control 3 Temperature sensor - evaporator 4 Actuator - air intake flap 5 Blower motor speed controller 6 Actuator - air distribution flap 7 Cam - air distribution control 1 2 3 E140028 5 7 6

412-01-11 Climate Control 412-01-11 DESCRIPTION AND OPERATION Overview of the climate control housing - vehicles with automatic temperature control 4 E140030 Item Description 1 Actuator - right-hand temperature flap 2 Lever - right-hand temperature control 3 Temperature sensor - evaporator 4 Actuator - air intake flap 5 Blower motor speed controller 6 Actuator - air distribution flap 7 Cam - air distribution control 8 Actuator - left-hand temperature control Lever - left-hand temperature control 1 2 3 E140028 6 5 7 8 Sun load sensor/interior temperature sensor - vehicles with automatic temperature control E140027 On vehicles with automatic temperature control, the sun load sensor measures the intensity of the sunlight reaching the vehicle and passes the values

412-01-12 Climate Control 412-01-12 DESCRIPTION AND OPERATION on to the A/C module. Additionally, the integrated in-car temperature sensor provides the A/C module with variable feedback from the cabin. The A/C module then ensures that the cabin temperature is regulated to customer comfort.

412-01-13 Climate Control 412-01-13 REMOVAL AND INSTALLATION Air Conditioning (A/C) Compressor – 2.5L Duratec-HE (122kW/165PS) - MI4(34 626 4) Materials Name Specification Compressor Oil - Air WSH-M1C231-B / Conditioning 6U7J-M1C231-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 2. Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 3. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 4. Torque: 15 Nm E129709 5. 1. Torque: 10 Nm 2. Torque: 25 Nm 1 1 2 x3 E130094 Installation 1. Coat the O-rings on the refrigerant lines. Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-AA) refrigerant oil 2. To install, reverse the removal procedure.

412-01-14 Climate Control 412-01-14 REMOVAL AND INSTALLATION Air Conditioning (A/C) Compressor – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma(34 626 4) Materials Name Specification Compressor Oil - Air WSH-M1C231-B / Conditioning 6U7J-M1C231-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 2. Refer to: Accessory Drive Belt - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-05 Accessory Drive - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 3. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 4. Torque: 15 Nm E129709 5. 1. Torque: 10 Nm 2. Torque: 25 Nm 2 x3 1 1 E130065 Installation 1. Coat the O-rings on the refrigerant lines. Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-AA) refrigerant oil 2. To install, reverse the removal procedure.

412-01-15 Climate Control 412-01-15 REMOVAL AND INSTALLATION Air Conditioning (A/C) Compressor – 3.2L Duratorq-TDCi (148kW/200PS) - Puma(34 626 4) Materials Name Specification Compressor Oil - Air WSH-M1C231-B / Conditioning 6U7J-M1C231-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 2. Refer to: Accessory Drive Belt - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-05 Accessory Drive - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 3. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 4. Torque: 15 Nm E129709 5. 1. Torque: 10 Nm 2. Torque: 25 Nm 2 x3 1 1 E130065 Installation 1. Coat the O-rings on the refrigerant lines. Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-AA) refrigerant oil 2. To install, reverse the removal procedure.

412-01-16 Climate Control 412-01-16 REMOVAL AND INSTALLATION Air Conditioning (A/C) Pressure Sensor Materials Name Specification Compressor Oil - Air WSH-M1C231-B / Conditioning 6U7J-M1C231-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Air Conditioning (A/C) System Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). Vehicles with automatic transmission 3. E140263 4. Torque: 8 Nm E140264 Vehicles with manual transmission 5. E129813 6. Torque: 8 Nm E140255 Installation 1. Coat the O-rings on the refrigerant lines. Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-AA) refrigerant oil 2. To install, reverse the removal procedure.

412-01-17 Climate Control 412-01-17 REMOVAL AND INSTALLATION Condenser – 2.5L Duratec-HE (122kW/165PS) - MI4 Materials Name Specification Compressor Oil - Air WSH-M1C231-B / Conditioning 6U7J-M1C231-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Air Conditioning (A/C) System Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 3. Refer to: Radiator Grille (501-08 Exterior Trim and Ornamentation, Removal and Installation). 4. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 5. Torque: 45 Nm E129709 6. E129813 7. CAUTION: All openings must be closed. Torque: 45 Nm E129814 8. E129801 9. E129802

412-01-18 Climate Control 412-01-18 REMOVAL AND INSTALLATION Installation 1. Coat the O-rings on the refrigerant lines. Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-AA) refrigerant oil 2. To install, reverse the removal procedure.

412-01-19 Climate Control 412-01-19 REMOVAL AND INSTALLATION Condenser – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma Materials Name Specification Compressor Oil - Air WSH-M1C231-B / Conditioning 6U7J-M1C231-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Air Conditioning (A/C) System Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 3. Refer to: Radiator Grille (501-08 Exterior Trim and Ornamentation, Removal and Installation). 4. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 5. Torque: 15 Nm E129709 6. E129812 7. CAUTION: All openings must be closed. Torque: 22 Nm E129800

412-01-20 Climate Control 412-01-20 REMOVAL AND INSTALLATION 8. Refer to: Charge Air Cooler (303-12 Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 9. E129801 10. E129802 Installation 1. Coat the O-rings on the refrigerant lines. Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-AA) refrigerant oil 2. To install, reverse the removal procedure.

412-01-21 Climate Control 412-01-21 REMOVAL AND INSTALLATION Receiver Drier Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 3. Torque: 15 Nm E129709 4. E129710 Installation 1. To install, reverse the removal procedure.

412-01-22 Climate Control 412-01-22 REMOVAL AND INSTALLATION Blower Motor – LHD 4WD/LHD RWD(34 374 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Glove Compartment (501-12 Instrument Panel and Console, Removal and Installation). 3. E129700 4. CAUTION: Do not put the blower motor down on the blower motor fan wheel. x3 E129701 Installation 1. NOTE: The component can only be installed in one position. To install, reverse the removal procedure.

412-01-23 Climate Control 412-01-23 REMOVAL AND INSTALLATION Blower Motor – RHD 4WD/RHD RWD(34 374 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Glove Compartment (501-12 Instrument Panel and Console, Removal and Installation). 3. E129698 4. CAUTION: Do not put the blower motor down on the blower motor fan wheel. x3 E129699 Installation 1. NOTE: The component can only be installed in one position. To install, reverse the removal procedure.

412-01-24 Climate Control 412-01-24 REMOVAL AND INSTALLATION Blower Motor Resistor(34 382 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Glove Compartment (501-12 Instrument Panel and Console, Removal and Installation). 2. E129882 3. Torque: 15 Nm E129883 Installation 1. To install, reverse the removal procedure.

412-01-25 Climate Control 412-01-25 REMOVAL AND INSTALLATION Climate Control Module Removal NOTE: Removal steps in this procedure may contain installation details. 2 E127928 2. E131167 1. x8 1 Installation 1. To install, reverse the removal procedure.

412-01-26 Climate Control 412-01-26 REMOVAL AND INSTALLATION Pollen Filter Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Glove Compartment (501-12 Instrument Panel and Console, Removal and Installation). 2. E129702 3. E129703 Installation 1. To install, reverse the removal procedure.

412-01-27 Climate Control 412-01-27 REMOVAL AND INSTALLATION Sunload Sensor(34 665 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Battery and Battery Charging Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 3. E129864 4. E129865 Installation 1. To install, reverse the removal procedure.

412-01-28 Climate Control 412-01-28 REMOVAL AND INSTALLATION Heater Core and Evaporator Core Housing Materials Name Specification Compressor Oil - Air WSH-M1C231-B / Conditioning 6U7J-M1C231-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 3. Refer to: Instrument Panel - RHD 4WD/RHD 5:' (501-12 Instrument Panel and Console, Removal and Installation). 4. E131211 5. Torque: 24 Nm E131212 6. x2 E131213 Vehicles with electronic automatic temperature control (EATC) 7.

412-01-29 Climate Control 412-01-29 REMOVAL AND INSTALLATION E131215 8. E132382 E131214 All vehicles 10. 1. Torque: 15 Nm 2. Torque: 7 Nm Vehicles with manual temperature control 9.

412-01-30 Climate Control 412-01-30 REMOVAL AND INSTALLATION x5 3 E131216 11. x2 E132403 x2 x3 2 1 12. E132404 Installation 1. Coat the O-rings on the refrigerant lines. Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-AA) refrigerant oil 2. To install, reverse the removal procedure.

412-01-31 Climate Control 412-01-31 REMOVAL AND INSTALLATION Evaporator Materials Name Specification Compressor Oil - Air WSH-M1C231-B / Conditioning 6U7J-M1C231-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Heater Core and Evaporator Core Housing (412-01 Climate Control, Removal and Installation). 2. x2 E132405 3. E132406 4. NOTE: Vehicles with electronic automatic temprature control only E131241

412-01-32 Climate Control 412-01-32 REMOVAL AND INSTALLATION 5. E131242 Installation 1. Coat the O-rings on the refrigerant lines. Material: Compressor Oil - Air Conditioning (WSH-M1C231-B / 6U7J-M1C231-AA) refrigerant oil 2. To install, reverse the removal procedure.

412-01-33 Climate Control 412-01-33 REMOVAL AND INSTALLATION Ambient Air Temperature Sensor(34 676 0) Removal NOTE: Removal steps in this procedure may contain installation details. x19 E140265 4. E140252 Installation 1. To install, reverse the removal procedure. 1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 3.