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Diagnostic Test

  1. CHECK FOR AN ACTIVE DTC 
    1. With the scan tool, read DTCs and record on the repair order.
    2. Record the Environmental Data.
    3. With the scan tool, erase DTCs.
    4. Using the recorded Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
    5. With the scan tool, read HVAC Module DTCs.

      Did the DTC return?

      Yes 

      • Go To  3

      No 

      • Go To  2
  2. PERFORM HVAC ACTUATOR CALIBRATION TEST AND CHECK FOR THE DTC TO RETURN 
    1. With the scan tool, perform the HVAC Actuator Calibration Test and recheck DTCs.

      Did the DTC return?

      Yes 

      • Go To  3

      No 

  3. CHECK ALL FIVE OF THE RECIRCULATION DOOR ACTUATOR CIRCUITS FOR AN OPEN/HIGH RESISTANCE 
    1. The ignition must be off when checking the continuity of a circuit.
    2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and the component harness connectors containing the circuit being tested. Note:  Use the wiring diagram as a guide to follow the path of the circuit. Check the disconnected connectors and related harnesses for damage, corrosion, and loose fitting terminals.
    3. Before testing a circuit, measure the resistance between the two leads of the Digital Volt-Ohm Meter (DVOM). Note:  Resistance in the meter leads can cause an error in the test results.
    4. Connect one lead of the DVOM to the circuit being tested at the component harness connector.
    5. Connect the other lead to the circuit being tested at the ECU harness connector and measure the resistance of the circuit.
    6. Repeat the steps above for each of the remaining circuits.
      NOTE:

      When back-probing a circuit at a harness connector, always use an appropriate back probing tool to prevent damage to the connector terminals.

      Is the resistance below 3.0 Ohms for all circuits?

      Yes 

      • Go To  4

      No 

      • Repair the applicable circuit for an open or high resistance.
      • Perform the HVAC VERIFICATION TEST. Refer to HVAC VERIFICATION TEST .
  4. INSPECT THE DOOR, DUCTS, AND LINKAGE FOR CONDITIONS THAT COULD CAUSE BINDING 
    1. Inspect the door and linkage for conditions that could cause the door to not move freely across the total travel of the door.
    2. Check for debris or objects in the ducts that could hinder the door movement.
    3. Inspect the door stops for damage.
    4. If necessary to gain access to the applicable door and ducts. Refer to HOUSING, HVAC, REMOVAL AND INSTALLATION .

      Were any problems found?

      Yes 

      • Repair the binding condition as necessary.
      • Perform the HVAC VERIFICATION TEST. Refer to HVAC VERIFICATION TEST .

      No 

      • Go To  5
  5. REPLACE THE RECIRCULATION DOOR ACTUATOR AND CHECK FOR THE DTC TO RETURN 
    1. Replace the Recirculation Door Actuator in accordance with the Service Information. Refer to ACTUATOR, RECIRCULATION DOOR, REMOVAL AND INSTALLATION .
    2. Connect the Recirculation Door Actuator, ECU, and any other disconnected harness connectors.
    3. Turn the ignition on.
    4. With the scan tool, erase DTCs.
    5. Using the Environmental Data and When Monitored conditions, operate the vehicle within the conditions that set the DTC.
    6. With the scan tool, read DTCs.

      Did the DTC return?

      Yes 

      • Go To  6

      No 

      • Replacing the Recirculation Door Actuator corrected the condition.
      • Perform the HVAC VERIFICATION TEST. Refer to HVAC VERIFICATION TEST .
  6. CHECK RELATED HARNESS CONNECTIONS 
    1. Disconnect all HVAC Module harness connectors.
    2. Disconnect all related in-line harness connections (if equipped).
    3. Disconnect the related component harness connectors.
    4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
      • Proper connector installation.
      • Damaged connector locks.
      • Corrosion.
      • Other signs of water intrusion.
      • Weather seal damage (if equipped).
      • Bent terminals.
      • Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
      • Terminals that have been pushed back into the connector cavity.
      • Perform a terminal drag test on each connector terminal to verify proper terminal tension.

      Repair any conditions that are found.

    5. Reconnect all HVAC Module harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
    6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
    7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
    8. With the scan tool, erase DTCs.
    9. Using the recorded Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
    10. With the scan tool, read HVAC Module DTCs.

      Did the DTC return?

      Yes 

      No 

      • The wiring or poor connection problem has been repaired.
      • Perform the HVAC VERIFICATION TEST. Refer to HVAC VERIFICATION TEST .
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