The air temperature controls are divided into 4 areas:

HVAC Control Module

The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module used for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the following features:

Air Temperature Actuator

The air temperature actuators are a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference, and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5, or 5-volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometers adjustable contact changes the door position signal between 0-5 volts.

The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates, the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts.

A/C Refrigerant Pressure Sensor

The A/C refrigerant pressure sensor is a 3-wire piezoelectric pressure transducer. A 5-volt reference, low reference, and signal circuits enable the sensor to operate. The A/C pressure signal can be between 0-5 volts. When the A/C refrigerant pressure is low, the signal value is near 0 volts. When the A/C refrigerant pressure is high, the signal value is near 5 volts. The powertrain control module (PCM) converts the voltage signal to a pressure value.

The A/C refrigerant pressure sensor protects the A/C system from operating when an excessively high pressure condition exists. The PCM disables the compressor clutch if the A/C pressure is more than 2 957 kPa (429 psi). The clutch will be enabled after the pressure decreases to less than 1 578 kPa (229 psi).

A/C Low Pressure Switch

The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 5 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 138-172 kPa (20-25 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275-317 kPa (40-46 psi). This enables the A/C compressor to turn back ON.

The low pressure switch uses refrigerant pressure to open and close a set of electrical contacts. When A/C request is authorized, the switch is closed and shows normal status. During this state, the switch will show 0 volts on the A/C low pressure sensor signal circuit. When A/C request is denied due to a low pressure condition, the switch will be open. During this state, the switch will show 5 volts on the A/C low pressure sensor signal circuit.

The purpose of the heating and A/C system is to provide heated and cooled air to the interior of the vehicle. The A/C system will also remove humidity from the interior and reduce windshield fogging. Regardless of the temperature setting, the following can effect the rate that the HVAC system can achieve the desired temperature:

The manual HVAC system is a dual temperature zone system. There are 2 separate air temperature levers. Moving the air temperature levers to the upward position diverts most of the airflow through the heater core, which increases the outlet air temperature. Moving the air temperature levers to the most downward position diverts most of the airflow around the heater core, which decreases the outlet air temperature. The air temperature offset can be as much as 16.7°C (30°F).

Pressing the A/C button enables the HVAC control module to request A/C compressor engagement and turn ON the A/C button LED. The HVAC control module sends a class 2 message to the powertrain control module (PCM) for A/C compressor engagement. The PCM will provide a ground for the A/C compressor relay enabling it to close its internal contacts to send battery voltage to the A/C compressor clutch coil. The A/C compressor diode will prevent a voltage spike, resulting from the collapse of the magnetic field of the coil, from entering the vehicle electrical system when the compressor is disengaged. Defrost and Defog mode selections will request A/C operation but not turn ON the A/C LED.

The following conditions must be met in order for the A/C compressor clutch to turn ON:

The HVAC control module monitors the A/C low pressure switch signal circuit. If the voltage signal on this circuit has no voltage drop, the module will interpret this condition as a low pressure, disabling the A/C request. The A/C low pressure switch will open its internal contacts at 151 kPa (22 psi). Then close the contacts at 275 kPa (40 psi) to resume A/C operation. This switch assists in cycling the A/C compressor and prevents A/C compressor operation if system has a low refrigerant level.

The PCM monitors the A/C refrigerant pressure sensor signal circuit. The voltage signal on this circuit is proportional to the refrigerant pressure inside the A/C high side pressure line. As the pressure inside the line increases, so does the voltage signal. If the pressure is above 2 957 kPa (429 psi), the A/C compressor output is disabled. When the pressure lowers to 1 578 kPa (229 psi), the PCM enables the compressor to operate.

The sensor information is used by the PCM to determine the following:

Once engaged, the compressor clutch will be disengaged for the following conditions:

Engine coolant is the essential element of the heating system. The thermostat controls the normal engine operating coolant temperature. The thermostat also creates a restriction for the cooling system that promotes a positive coolant flow and helps prevent cavitation.

Coolant enters the heater core through the inlet heater hose, in a pressurized state. The heater core is located inside the HVAC module. The ambient air drawn through the HVAC module absorbs the heat of the coolant flowing through the heater core. Heated air is distributed to the passenger compartment, through the HVAC module, for passenger comfort. Opening or closing the air temperature door controls the amount of heat delivered to the passenger compartment. The coolant exits the heater core through the return heater hose and recirculated back through the engine cooling system.

Refrigerant is the key element in an air conditioning system. R-134a is presently the only EPA approved refrigerant for automotive use. R-134a is an very low temperature gas that can transfer the undesirable heat and moisture from the passenger compartment to the outside air.

The A/C compressor is belt driven and operates when the magnetic clutch is engaged. The compressor builds pressure on the vapor refrigerant. Compressing the refrigerant also adds heat to the refrigerant. The refrigerant is discharged from the compressor, through the discharge hose, and forced to flow to the condenser and then through the balance of the A/C system. The A/C system is mechanically protected with the use of a high pressure relief valve. If the A/C refrigerant pressure sensor were to fail or if the refrigerant system becomes restricted and refrigerant pressure continued to rise, the high pressure relief will pop open and release refrigerant from the system.

Compressed refrigerant enters the condenser in a high temperature, high pressure vapor state. As the refrigerant flows through the condenser, the heat of the refrigerant is transferred to the ambient air passing through the condenser. Cooling the refrigerant causes the refrigerant to condense and change from a vapor to a liquid state.

The condenser is located in front of the radiator for maximum heat transfer. The condenser is made of aluminum tubing and aluminum cooling fins, which allows rapid heat transfer for the refrigerant. The semi-cooled liquid refrigerant exits the condenser and flows through the liquid line, to the orifice tube.

The orifice tube is located in the liquid line between the condenser and the evaporator. The orifice tube is the dividing point for the high and the low pressure sides of the A/C system. As the refrigerant passes through the orifice tube, the pressure on the refrigerant is lowered. Due to the pressure differential on the liquid refrigerant, the refrigerant will begin to vaporize at the orifice tube. The orifice tube also meters the amount of liquid refrigerant that can flow into the evaporator.

Refrigerant exiting the orifice tube flows into the evaporator core in a low pressure, liquid state. Ambient air is drawn through the HVAC module and passes through the evaporator core. Warm and moist air will cause the liquid refrigerant boil inside of the evaporator core. The boiling refrigerant absorbs heat from the ambient air and draws moisture onto the evaporator. The refrigerant exits the evaporator through the suction line and back to the compressor, in a vapor state, and completing the A/C cycle of heat removal. At the compressor, the refrigerant is compressed again and the cycle of heat removal is repeated.

The conditioned air is distributed through the HVAC module for passenger comfort. The heat and moisture removed from the passenger compartment will also change form, or condense, and is discharged from the HVAC module as water.