IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)

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Title : 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Applies To : TerraStar and TranStar Models Only

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
05/04/2017 ‐ Removed rear HVAC diagnostics and coded to TerraStar and TranStar only.
12/19/2016 ‐ Removed retired links
06/01/2016 ‐ Corrected diagnostic table layout
09/01/2015 ‐ Repaired iKNow link in step 7
06/30/2015 ‐ Changed formatting of tables in Diagnostic section to fit on one page when printed.
08/31/2015 ‐ Fixed hyperlink.





DESCRIPTION
This document addresses Air Conditioning issues on the following 2010 to 2014 TerraStar and TranStar
models.
The following procedures will guide the user through : Common Air Conditioning failure areas, diagnostic tools,
SRTs, and warranty filing.
Note: For anything Pre-2010, reference the Pre-2010 A/C HVAC Resource Center located IK1900156.

SYMPTOM
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
SPN

FMI Description

2609

16

A/C High Pressure Protection

2609

15

Low Charge Protection

1079

1

5 volt sensor supply below normal

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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)

3985

9

A/C Control Head Circuit Failed To Communicate With Body Controller

1552

2

A/C Control Head Temperature Mix DM1

3981

2

A/C Control Head Mode Fault DM1

3984

2

A/C Control Head Air Inlet DM1

2058

9

Rear A/C Data Link Communication Failure

2058

14

Rear A/C Data Link Communication Failure

3982

2

A/C Rear Blower Speed Control Switch Error

3983

2

Rear A/C Temperature Control Switch Error

520465 2

Page 2 of 6

A/C Control Head Multiple Motor Faults

Customer Observations or Concerns:
•
•
•
•
•
•

Malfunction Indicator Light (MIL)
No cab air conditioning
"Warm" A/C
No air flow through vents
No rear A/C
Inoperative MaxxPro no-idle A/C system

SPECIAL TOOLS / SOFTWARE
Tool Description

Tool
Number

Comments

Robinair Air Conditioning Machine
or equivalent

34988

A/C recovery, vac, and
performance test

Instructions

SERVICE PARTS INFORMATION
Due to variety of configurations, reference the parts catalog for vehicle being repaired.
Parts Catalog

PROCEDURE OVERVIEW

Do not start engine until steps 2-4 have been completed. If the engine has been run
recently, allow the vehicle to sit for one hour so system pressures can stabilize.
Consider the following before beginning:
• Are any Air Conditioning related AFC’s open?
• Was the vehicle recently in for an Air Conditioning repair, in which the system was not properly filled or
serviced?
• Were A/C repairs made recently, and fault codes not cleared properly?
If the A/C issue is known (blown off hose, visible dye, inoperative blower motor) go directly to the respective
steps or iKNow articles listed below. Otherwise, go to step 1.
• IK1900226 A/C Control Head Issues
• IK1900225 A/C Mechanical Pressures diagnostics
• IK1900223 A/C Sensor/ Electronic Issues

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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)

Page 3 of 6

DIAGNOSTIC STEPS

Step Action

Decision

Preliminary checks:
Note: Do not start engine until steps 2-4 have been completed. If the
engine has been run recently, allow the vehicle to sit for one hour to
allow system pressures to stabilize.
Perform a visual check of the A/C system to verify that no obvious
problems are present. With the engine off, inspect the following
items:

1

•
•
•
•
•
•
•
•
•
•
•
•

Compressor and clutch mounting
Compressor clutch coil wiring and connection
Compressor drive belt and belt tensioner
A/C hoses and connections
Condenser mounting
Condenser fins (blockage by debris)
Receiver-drier mounting
Expansion valve mounting
Filter element
Fresh air module drains
Fresh air module mounting and overall condition
Electrical connections to pressure transducer and low pressure
switch
• Electrical connections to actuators for airflow doors (recirculate,
temperature, and mode doors)
• Fan speeds and mode door operation

Yes: Repair as necessary.
Restore system to operational
condition and operate the A/C
system to determine if the
complaint was corrected.

No: Go to step 2.

Were any issues found?

Step Action

Diagnostic Trouble Codes:
2

Check for A/C related DTC’s:

Decision

Yes: Go to FAULT CODES in
IK1900207

Are any A/C related DTC’s found?
No: Go to step 3.

Step Action
3

Static Pressure:

Decision
Yes: Go to step 4.

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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)

NOTE: Have the engine OFF and A/C system at ambient
temperature when measuring static pressure.If the engine has been
run recently, allow the vehicle to sit for a minimum of one hour to
allow system pressures and temperatures to stabilize.

Page 4 of 6

No: Go to Air Conditioning
Mechanical Pressures
Diagnostics IK1900225

1. Inspect high and low side Schrader valves for presence of dye
and pooling of oil in valve.
2. Connect gauges to the A/C system and record static pressure
readings.
3. Use a temperature probe to determine the ambient temperature
within 1 or 2 degrees. Record the measured temperature.
4. Locate the ambient temperature on the chart below and
compare the vehicle’s static pressure to the chart pressure.
Temp °F Temp °C R134A PSIG
40 °F

4.4 °C

35

45 °F

7.2 °C

40

50 °F

10.0 °C

45

55 °F

12.8 °C

51

60 °F

15.6 °C

57

65 °F

18.3 °C

64

70 °F

21.1 °C

71

75 °F

23.9 °C

78

80 °F

26.6 °C

86

85 °F

29.4 °C

95

90 °F

32.2 °C

104

95 °F

35.0 °C

113

100 °F

37.7 °C

124

105 °F

40.5 °C

134

110 °F

43.3 °C

146

Are the A/C pressures in spec?

Step Action

Decision
Yes: Go to step 5.

Compressor Engagement:
4

Start engine. Turn the A/C on. Verify compressor engagement.
Does the compressor engage?

No: Go to Air Conditioning
Electrical Diagnostics
IK1900223

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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)

Step Action
C. Engage the engine cooling fan (unless viscous fan drive).
D. Close the hood, being careful not to damage the equipment.
E. Insert a thermometer into the passenger side, left instrument
panel vent. Do not allow the thermometer to touch the sides of
the duct. Insert a second thermometer into the lower passenger
bunk vent.
F. Start the engine and raise the idle speed to 1500 rpm.

Page 5 of 6

Decision
Yes: System is operating
correctly. Discuss concern with
customer.
No: Gauge readings are out of
specification: Go to Air
Conditioning Mechanical
Pressures Diagnostics
IK1900225

G. Open windows and close both cab doors.
H. Set the mode control to: NORM A/C; Highest blower speed;
Coldest cooling temperature.

5

I. Operate the system for five minutes, or until gauge readings
settle.
J. Record the following data:
Test Point

Value

Ambient Air Temperature
Relative Humidity

No: Gauge readings are
correct but cab vent
temperature is out of
specification: Go to Air
Conditioning Control Head
Diagnostics IK1900226

Cab Air duct Temp
Low-Side psi @ 1500 RPM
Compressor on (cut-in PSI)
Compressor off (cut-out PSI)
High-Side psi @ 1500 RPM
Compressor on (cut-in PSI)
Compressor off (cut-out PSI)
Lower Passenger bunk vent
temp

WARRANTY INFORMATION
K. Compare gauge readings, vent temperature, ambient
temperature,
to the of
appropriate
HVAC System
Standard Repair
Times:and
Duehumidity
to the variety
vehicle confirgurations
and number of components affected,
Pressure
Test
Chart.
reference the SRT Manual (quick links below) for repair times.
Does the Cab and rear HVAC operate correctly?
Description
A/C SYSTEM PRELIMINARY DIAGNOSIS (EXCEPT 5000, 9000 SERIES), PERFORM
A/C MECHANICAL PRESSURES DIAGNOSIS (EXCEPT 5000, 9000 SERIES), PERFORM
A/C ELECTRICAL DIAGNOSIS ( EXCEPT 5000, 9000 SERIES) , PERFORM
A/C CONTROL HEAD DIAGNOSIS
A/C REAR UNIT ELECTRICAL AND MECHANICAL DIAGNOSIS (EXCEPT 5000,9000 SERIES),
PERFORM
SRT Manual

OTHER RESOURCES

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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)

Page 6 of 6

Document
Number

Description

S16046

HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 - 3200 Bus, DuraStar®,
TerraStar™, TranStar®, WorkStar® Models

0000002221

HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 ProStar and LoneStar
Models (Formerly S16047)

IK1900207

2010 and Later ProStar and LoneStar HVAC Information

IK1900022

A/C Refrigerant and Oil Capacities

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