SECTION 2F HVAC OCCUPANT CLIMATE CONTROL

(AUTO A/C) – DIAGNOSTICS

IMPORTANT

Before performing any Service Operation or other procedure described in this Section, refer to

Section 00, CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or

property damage.

CONTENTS

1. DIAGNOSTICS

1.1 TECH 2 DIAGNOSTICS

1.2 TECH 2 TEST MODES AND DISPLAYS FOR OCC

DIAGNOSIS

2. DIAGNOSTIC CHARTS

CHART A – DIAGNOSTIC CIRCUIT CHECK

CHART B – OCC SYSTEM DOES NOT POWER

DTC 13 – AMBIENT TEMPERATURE SENSOR

VOLTAGE TOO HIGH

DTC 14 – AMBIENT TEMPERATURE SENSOR

VOLTAGE TOO LOW

DTC 15 – IN-CAR TEMPERATURE SENSOR

VOLTAGE TOO HIGH

DTC 16 – IN-CAR TEMPERATURE SENSOR

VOLTAGE TOO LOW

DTC 17 – EVAPORATIVE TEMPERATURE

SENSOR VOLTAGE TOO HIGH (LHD)

DTC 17 – EVAPORATIVE TEMPERATURE

SENSOR VOLTAGE TOO HIGH (RHD)

DTC 18 – EVAPORATIVE TEMPERATURE

SENSOR VOLTAGE TOO LOW (LHD)

DTC 18 – EVAPORATIVE TEMPERATURE

SENSOR VOLTAGE TOO LOW (RHD)

DTC 19 – SUN LOAD SENSOR ERROR

DTC 35 – NO SERIAL DATA FROM PCM

DTC 36 – NO SERIAL DATA FROM BCM

DTC 37 – ROM CHECKSUM ERROR

DTC 38 – EEPROM CHECKSUM ERROR

DTC 39 – RAM ERROR

DTC 40 – AIR MIX DOOR MOTOR DRIVER

ERROR (LHD)

DTC 40 – AIR MIX DOOR MOTOR DRIVER

ERROR (RHD DRIVERS SIDE MOTOR)

DTC 40 – AIR MIX DOOR MOTOR DRIVER

ERROR (RHD PASSENGERS SIDE MOTOR)

DTC 41 – SOLENOID DRIVER ERROR – LHD

DTC 41 – SOLENOID DRIVER ERROR – RHD

DTC 43 – DRIVER’S AIR MIX DOOR MOTOR

FEEDBACK CIRCUIT VOLTAGE TOO LOW

(LHD)

DTC 43 – DRIVERS AIR MIX DOOR MOTOR

FEEDBACK CIRCUIT VOLTAGE TOO LOW

(RHD)

DTC 44 – DRIVERS AIR MIX DOOR MOTOR

FEEDBACK CIRCUIT VOLTAGE TOO HIGH

(LHD)

DTC 44 – DRIVERS AIR MIX DOOR MOTOR

FEEDBACK CIRCUIT VOLTAGE TOO HIGH

(RHD)

DTC 45 – PASSENGERS AIR MIX DOOR

MOTOR FEEDBACK CIRCUIT VOLTAGE TOO

LOW

DTC 46 – PASSENGERS AIR MIX DOOR

MOTOR FEEDBACK CIRCUIT ZOLTAGE TOO

HIGH

DTC 47 – DRIVER AIR MIX MIN. CALIBRATION

ERROR (LHD)

DTC 47 – DRIVER AIR MIX MIN. CALIBRATION

ERROR (RHD)

DTC 48 – DRIVER AIR MIX MAX. CALIBRATION

ERROR (LHD)

DTC 48 – DRIVER AIR MIX MAX. CALIBRATION

ERROR (RHD)

DTC 49 – PASS AIR MIX MIN. CALIBRATION

ERROR

DTC 50 – PASS AIR MIX MAX. CALIBRATION

ERROR

3. ELECTRICAL COMPONENT TESTS

3.1 IN CAR TEMPERATURE SENSOR

3.2 EVAPORATIVE TEMPERATURE SENSOR TEST

LEFT-HAND DRIVE

RIGHT-HAND DRIVE

3.3 AMBIENT TEMPERATURE SENSOR

3.4 OCC BLOWER MOTOR RESISTOR

LEFT-HAND DRIVE

RIGHT-HAND DRIVE

3.5 VACUUM SOLENOID PACK

LEFT-HAND DRIVE

RIGHT-HAND DRIVE

3.6 WATER VALVE VACUUM SWITCH VALVE

4. VACUUM RETENTION TESTS

VACUUM LOSS DEFAULT SETTINGS

4.1 VACUUM SOLENOID PACK

4.2 VACUUM ACTUATOR LINES

LEFT- HAND DRIVE

RIGHT- HAND DRIVE

4.3 VACUUM MANIFOLD LINE

LEFT-HAND DRIVE

RIGHT-HAND DRIVE

4.4 WATER VALVE VACUUM SWITCH

5. WIRING DIAGRAMS

CONNECTORS: OCC SYSTEM

CONNECTORS: OCC SYSTEM CONTINUED

WIRING DIAGRAM: OCC SYSTEM – V6 LHD

WIRING DIAGRAM: OCC SYSTEM – V6 RHD

WIRING DIAGRAM: OCC SYSTEM – GEN III V8

LHD

WIRING DIAGRAM: OCC SYSTEM – GEN III V8

RHD

6. SPECIAL TOOLS

Techline

1. DIAGNOSTICS

1.1 TECH 2 DIAGNOSTICS

TECH 2 is a hand-held diagnostic computer

designed specifically to help Holden Retailer

technicians to diagnose and repair electronic

systems used on Holden vehicles.

TECH 2, with the appropriate software, cables and

adaptors, is capable of reading serial d ata when

connected to the Data Link Connecto r (DLC). The

DLC is located in the instrument panel lower right-

hand trim, to the right of the steering column.

Legend

1. Data Link Connector (DLC)

2. DLC Adaptor

3. DLC Cable

4. TECH 2 diagnostic tool.

For additional general information on connecting

and operating TECH 2, refer to Section 0C,

TECH 2.

Figure 2F-1

TECH 2 has six test modes for diagnosing the

Occupant Climate Control (OCC system. The six

test modes are as follows:

Mode F0: Normal Mode

In this mode, the TECH 2 monitors the

communication between control modules on the

serial data line. The information displayed on the

TECH 2 screen in this mode is what the OCC is

communicating to the othe r modules via the serial

data line.

Mode F1: Diagnostic Tro uble Codes (DTC)

In this test mode, the operator of TECH 2 has the

option of reading current and history DTC’s or

clearing stored DTC’s from the control module’s

memory.

Mode F2: Data Display

In this test mode, TECH 2 displays the status of

inputs and outputs of the OCC.

Mode F3: Snapshot

In this test mode, TECH 2 captures OCC data

before and after a forced manual tri gger.

Mode F4: Miscellaneous Tests

In this test mode, the TECH 2 performs system

functional tests to assist in problem isolat ion during

troubleshooting.

Each test mode has specific diag nosis capabilities

that depend upon various function key entry on

TECH 2.

Mode F5: Program

In this test mode, TECH 2 allows the programming

of various OCC features (e.g. calibration of driver’s

air mix door).

Figure 2F-2

1.2 TECH 2 TEST MODES AND DISPLAYS FOR OCC DIAGNOSIS

A prerequisite to this diagnostic section is for the user to be familiar with the proper use of TECH 2. The following

pages illustrate only the major TECH 2 scree n displays and provide a brief explanation of their function for

diagnosing the OCC. If additional information is required on the operation of TECH 2, reference should be made to

either Section 0C TECH 2 or the TECH 2 OPERATOR’S MANUAL.

System Selection Menu

With TECH 2 connected to the DLC, select

F0: Diagnostics selected from the Main Menu, the

correct Model Year and Vehicle Type must be

selected for access to the System Selection Menu.

Select F3: Body.

This mode contains all functions to test, diagnose,

monitor and program the vehicle’s body systems

including the OCC as well as providing the

opportunity to check all DTC’s that may be set in

the vehicle.

Figure 2F-3

The correct Model Year is then selected.

Figure 2F-4

The Vehicle Type is then selected.

Figure 2F-5

Select F3: Body.

This mode contains all functions to test, diagnose,

monitor and program the vehicle’s body systems

including the OCC as well as providing the means

to check all DTC’s that may be set in the vehicle.

Figure 2F-6

Body Application Menu

Once F3: Body has been selected from the System

Select Menu, Occupant Climate Cont rol can be

selected.

Select Occupant Climate Control.

NOTE: If information regarding DTC’s set for the

vehicle is required, select DTC Check and press

enter to continue. To return to the OCC mode

option from the DTC Check mode option screen

display, simply press the EXIT key on TECH 2.

Once the OCC has been selected, the following

two System Identification screens will appear which

require action.

Figure 2F-7

System Identification

Turn the ignition ON (as requested) and press

CONFIRM soft key to continue.

Figure 2F-8

The System Identification screen will then display

OCC system control module identification data.

Press the CONFIRM soft key to continue to the

OCC Application Menu.

Figure 2F-9

Body Menu

The following functions will now be available:

F0: Normal Mode

F1: Diagnostic Trouble Codes

F2: Data Display

F3: Snapshot

F4: Miscellaneous Tests

F5: Program

Figure 2F-10

F0: NORMAL MODE

In the F0: Normal Mode, information that the OCC

control module is communicating to other control

modules, via the serial data line, is displayed.

For example: As displayed opposite, the A/C

request status is ‘(Air Condit off’. This means the

OCC control module is communicating with the

BCM, informing that the air conditioning

compressor is currently turned off.

Figure 2F-11

F1: DIAGNOSTIC TRO UBLE CODES (DTC)

If F1: Diagnostic Trouble Codes is selected, a

selection list is displayed which contains:

F0: Read DTC Informa tion: In this mode, a listing

of all (if any) current DTC numbers, together with a

brief description of the DTC, will be displayed. A

listing of the last two stored DTC’s will be

displayed, together with a brief description of the

DTC and the number of ignition cycles since the

DTC occurre d.

NOTE: If any DTC’s are set, reference sh ould be

made to the relevant diagnostic charts in this

Section.

F2: Clear DTC Informatio n: In this mode, DTC’s

can be cleared by simply selecting F2: Clea r DTC

Information and pressing the enter key on TECH 2.

The following table sets out all the possible

diagnostic trouble codes as indicated by TECH 2.

Figure 2F-12

The following table lists all OCC system DTCs applica ble to MY2003 VY and V2 Series vehicles.

DTC CODE DESCRIPTION

13 Ambient temperature sensor voltage too high

14 Ambient temperature sensor voltage too low

15 In car temperature sensor voltage too high

16 In car temperature sensor voltage too low

17 Evaporative temperature sensor voltage too high

18 Evaporative temperature sensor voltage too low

19 Sun load sensor error

35 No serial data from PCM

36 No serial data from BCM

37 ROM checksum error

38 EEPROM checksum error

39 RAM error

40 Air mix door motor driver error

41 Solenoid driver error

43 Driver’s air mix door motor feedback circuit voltage

too low

44 Driver’s air mix door motor feedback circuit voltage

too high

45 Passenger’s air mix door motor feedback circuit

voltage too low

46 Passenger’s air mix door motor feedback circuit

voltage too high

47 Driver Airmix Min. Calibration Erro r

48 Driver Airmix Max. Calibration Error

49 Pass Airmix Min. Calibration Error

50 Pass Airmix Max. Calibration Erro r

NOTE: for diagnosis of the pressure transducer, refer to the following Sections in the MY2003 VY and V2 Series

Service Information:

• Section 6C1 POWERTRAIN CONTROL MODULE – V6 ENGINE.

• Section 6C2 POWERTRAIN CO NTROL MODULE – V6 SUPERCHARGED ENGINE.

• Section 6C3 POWERTRAIN CONTROL MODULE – GEN III V8.

F2: DATA DISPLAY

If the F2: Data Display mode is selected, an additional menu will appear giving the operator th e option of selecting:

• F1: OCC Data List,

• F2: OCC Switch Data,

• F3: System Identification or,

• Air Mix Door Calibration Position s.

F0: Data List

The data list displays inputs and o utputs of the

OCC system. When F2: DATA DISPLAY is

selected followed by F0: DATA LIST, the Switch

Data Table will be displayed.

Figure 2F-13

The following table shows all items in the DATA LIST, together with their expected readings:

OCC TYPE

DATA LIST READING Single Zone Dual Zone

System Status On/Off X X

Battery Voltage Approx 13.5 V X X

Ignition Status OFF/ON X X

Air Conditioning Request NO/YES X X

Evaporative Temperature Sensor 0 to 5.0 ± 0.2 V X X

Evaporative Temperature °C X X

Ambient Temperature Sensor 0 to 5.0 ± 0.2 V X X

Ambient Temperature Degrees °C X X

Dampened Ambient Temperature Degrees °C X X

In Car Temperature Sensor 0 to 5.0 ± 0.2 V X X

In Car Temperature Degrees °C X X

Blower Fan Speed Manual: 1234 and HIGH, Auto: Low, Mid and High X X

Desired Blower Fan Speed % X X

Blower Fan Speed Control % X X

Blower Fan Speed Feedback Voltage V X X

Drivers Air Mix Motor Position Desired % X X

Drivers Air Mix Motor Position Feedback % X X

Drivers Air Mix Motor Position Feedback Voltage 0 to 5.0 ± 0.2 V X X

Passengers Air Mix Motor Position Desired % X

Passengers Air Mix Motor Position Feedback % X

Passengers Air Mix Motor Position Feedback Voltage 0 to 5.0 ± 0.2 V X

Engine Coolant Temperature Degrees °C X X

Sun Load Steps: 0 – 255 X X

Driver Set Temperature Degrees °C X X

Passengers Set Temperature Degrees °C X

Operating Mode Manual/auto X X

Outlet Mode Face / floor / blend / foot X X

Inlet Mode Fresh / Recirc X X

Startup Strategy None, Recirc / Delay, Demist / Delay, Purge,

A/C Purge, Fresh / Delay X X

Fresh / Recirculation Solenoid Off/On X X

Water Valve Solenoid Off/On X X

Water Valve Closed/Open X X

Face 2 Solenoid Off/On X X

Face 1 Solenoid Off/On X X

Foot 2 Solenoid Off/On X X

Foot 1 Solenoid Off/On X X

High Fan Relay Inactive: 12 V Active: 0 V X X

Rear Demist Relay Off/On X X

Park Lamp Input Off/On X X

Front Demist LED Off/On X X

Rear Demist LED Off/On X X

F1: Switch Data

In this mode, the operator is able to test the

function of each switch on the OCC control module.

When F2: DATA DISPLAY is selected followed by

F1: SWITCH DATA, the Switch Data Table will be

displayed.

NOTE: The OCC control module buttons will need

to be held on when carrying out this test due to a

normal delay in information transfer.

To test the OCC control module switches in this

mode, turn on the ignition and the OCC system.

Activate each switch on the OCC cont rol module

and observe the TECH 2 screen to see if the

TECH 2 display changes the switch status from Off

to On.

Figure 2F-14

Figure 2F-15 shows the OCC switch configuration applicable to LHD models. The table following shows all items in

the SWITCH DATA, the switch graphics and their expected test readings. Switch progression of the table follows

the switch layout of the LHD OCC control module. Turn each switch on and off beginning at the OFF side of the

OFF/AUTO switch (1) and progre ss down through the right-hand side switch cluster. Move to the left-hand side

switch cluster and begi nning at the T side of the blower fan switch (2), turn each switch on and off.

Figure 2F-15

SWITCH DATA SWITCH READING

Off Switch Off/On

Auto Switch Off/On

Minimum Temperature Switch Off/On

Maximum Temperature Switch Off/On

Recirculation Switch Off/On

Front Demist Switch Off/On

Rear Demist Switch Off/On

Fan Down Switch Off/On

Fan Up Switch Off/On

Driver Temp. Down Switch (Temperature) Off/On

Driver Temp. Up Switch (Temperature) Off/On

Mode Switch Off/On

Outside Temperature Switch Off/On

Air Conditioning Switch Off/On

Figure 2F-16 shows the OCC switch configuration applicable to RHD single zone models. The table following

shows all items in the SWITCH DATA, the switch graphics and their expected test readings. Switch prog ression of

the table follows the switch layout of the RHD single zone OCC control module. Turn ea ch switch on and off

beginning at the OFF side of the OFF/AUTO switch (1) and progress down through the right-hand side switch

cluster. Move to the left-hand side switch cluster and beginning at the T side of the blower fa n switch (2), turn each

switch on and off.

Figure 2F-16

SWITCH DATA SWITCH READING

Off Switch Off/On

Auto Switch Off/On

Driver Temp. Down Switch (Temperature) Off/On

Driver Temp. Up Switch (Temperature) Off/On

Recirculation Switch Off/On

Front Demist Switch Off/On

Rear Demist Switch Off/On

Fan Down Switch Off/On

Fan Up Switch Off/On

Minimum Temperature Switch Off/On

Maximum Temperature Switch Off/On

Mode Switch Off/On

Outside Temperature Switch Off/On

Air Conditioning Switch Off/On

Figure 2F-17 shows the OCC switch configuration applicable to RHD dual zone models. The table following shows

all items in the SWITCH DATA, the switch graphics and their expected test readings. Switch progre ssion of the

table follows the switch layout of the RHD dual zone OCC control module. Turn each switch on and off beginning at

the OFF side of the OFF/AUTO switch (1) and p ro gress down through the right-hand side switch cluster. Move to

the left-hand side switch cluster and beginning at the T side of the blower fan switch (2), turn each switch on and

off.

Figure 2F-17

SWITCH DATA SWITCH READING

Off Switch Off/On

Auto Switch Off/On

Driver Temp. Down Switch (Temperature) Off/On

Driver Temp. Up Switch (Temperature) Off/On

Recirculation Switch Off/On

Front Demist Switch Off/On

Rear Demist Switch Off/On

Fan Down Switch Off/On

Fan Up Switch Off/On

Passenger Temp. Down Switch

(Temperature) Off/On

Passenger Temp. Up Switch

(Temperature) Off/On

Mode Switch Off/On

Outside Temperature Switch Off/On

Air Conditioning Switch Off/On

F2: System Identification

When F2: DATA DISPLAY is selected followed by

F2: SYSTEM IDENTIFICATION, the System

Identification will be displayed.

Figure 2F-18

In this mode, the operator is able to view the

System Identification screen, which will display

OCC system control module identification data.

Figure 2F-19

F3: Air Mix Door Calibration Positions

When F2: DATA DISPLAY is selected followed by

F3: AIR MIX DOOR CALIBRATION POSITIONS,

the System Identification will be displayed.

Figure 2F-20

In this mode, the operator is able to view the results

of the last air mix door calibration.

Figure 2F-21

The air mix doors can be calibrated by selecting

F5: Program in the Body menu. To carry out an air

mix door calibration, refer to F5: PROGRAM in this

Section.

Figure 2F-22

F3: SNAPSHOT

In this test mode, the TECH 2 captures OCC data before and after a forced manual trigger.

F4: MISCELLANEOUS TESTs

In the Miscellaneous Test mode, tests can be carried out to the OCC system that will test for proper operation of

the various OCC functions. In this mode, testing and observing the results can confirm correct operation or identify

error conditions.

NOTE: During the Miscellaneous Tests, the blower fan will be driven at approximately 60% for all tests excluding

the Blower Speed test.

When Miscellaneous Tests is sele cted, the first

nine tests will be displayed.

Figure 2F-23

When the menu is scrolled downward with the

down soft key, the remaining test options are

displayed.

Figure 2F-24

Driver’s Air Mix Door

PURPOSE OF TEST:

Monitor the face vent to verify that a temperature

change takes place when opening and closing the

air mix door, indicating both air mix motor and door

movement.

PRE-CONDITIONS:

Engine running at operating temperature.

PROCEDURE:

Insert a thermometer into the centre face vent

(right-hand side centre vent for dual zone). With

TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Driver’s Side Air Mix Door.

Conduct the Drivers Side Air Mix Door test by

using the increase/decrease soft keys on TECH 2

open and close the air mix door. The range is

variable from 9% closed to 100% open.

When the door is open (increase % opening), the

temperature at the centre vent should increase.

When the door is closed (decrease % opening), the

temperature at the centre vent should decrease.

Figure 2F-25

Passenger’s Air Mix Door

PURPOSE OF TEST:

Monitor the face vent to verify that a temperature

change takes place when opening and closing the

air mix door, indicating both air mix motor and door

movement.

PRE-CONDITIONS:

Engine running at operating temperature.

PROCEDURE:

Insert a thermometer into the left side of the centre

face vent. With TECH 2 connected to the DLC

select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Passenger’s Side Air Mix Door.

Conduct the Passenger Side Air Mix Door test by

using the increase/decrease soft keys on TECH 2

open and close the air mix door. The range is

variable from 9% closed to 100% open.

When the door is open (increase % opening), the

temperature at the centre vent should increase.

When the door is closed (decrease % opening), the

temperature at the centre vent should decrease.

Figure 2F-26

Blower Speed

PURPOSE OF TEST:

To ensure that all blower speeds are preset and

the blower motor circuit is functional.

PRE-CONDITION:

Engine running

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Blower Speed.

Using the increase soft key on TECH 2, command

the blower fan to maximum – 100%.

Using the decrease soft key on TECH 2, command

the blower fan to minimum – 0%.

Each soft key increase or decrease will alter fan

speed by a 10% increment.

NOTE: Blower fan speeds are dependant on

vehicle battery voltage.

Figure 2F-27

Maximum Fan Relay

PURPOSE OF TEST:

To ensure a circuit exists between the OCC control

module, the relay and the blower fan.

PRE-CONDITION:

Engine off.

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Maximum Fan Relay.

Figure 2F-28

Conduct the Maximum Fan Relay test by using the On soft key to activate the relay and maximum fan sp eed.

Use the Off soft key to deactivate relay and turn blower speed off. The maximum fan relay (1) is labelled

BLOWER FAN RELAY and is located in the engine compa rtment fuse and relay housing (2). Listen or feel for

the relay activating (clickin g) wh en the On and Off soft keys are activated on TECH 2. If the relay does not

activate, temporarily substitute with a serviceable relay from an adjacent installation. If the substitute relay

does not activate, refer to Chart A in 2. DIAGNOSTIC CHARTS in this Section.

Figure 2F-29

LCD Display Test

PURPOSE OF TEST:

To ensure that all segments are functioning an d

can be displayed on the OCC control module LCD

screen.

PRE-CONDITION:

Engine not running.

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

LCD Display Test.

Using the On/Off soft keys on TECH 2, activate

and deactivate the LCD. An LCD screen displaying

all segments should appear for approximately

5 seconds after the On soft key is activated.

Pressing the Off key will turn all segments off for

approximately 5 seconds but the LCD screen will

remain illuminated during this procedure.

Figure 2F-30

Figure 2F-31

Figure 2F-32

Outlet Mode

PURPOSE OF TEST:

To ensure that the vacuum solenoids, vacuum

supply and mode doors are functional.

PRE-CONDITION:

Engine running.

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Outlet Mode.

Conduct Outlet Mode test by using the up/down

soft keys on TECH 2 and scrolling through each

mode position; Demist, Face, Foot/Face (Bi-level),

Demist/Foot (Blend) and Foot.

The OCC control module LCD indicates the

position that the air will be directed to. During this

test the blower fan will be driven at approximately

60%.

Feel for air movement at the direction indicated by

the mode graphic on the OCC control module LCD

screen.

When the Demist Mode is selected, air i s

distributed from demist ducts only. The demist ico n

(1) will be displayed on the LCD screen.

When Face Vent Mode is selected air is distributed

from the centre and side vents. The fa ce icon (1)

will be displayed on the LCD screen.

NOTE: On dual zon e sy stems, when the Face Vent

Mode is selected, air will be distributed from left

and right or the centre face vent.

When the Face/Foot (Bi-Level) Mode is sele cted,

air is distributed from face, side and floor ducts.

The bi-level icon (1) will be displayed on the LCD

screen.

Figure 2F-33

Figure 2F-34

Figure 2F-35

Figure 2F-36

When the Demist/Foot (Blend) Mode is selected,

air is distributed from demist ducts and the floor.

The demist and foot icons (1) will be displayed on

the LCD screen.

When the Foot (Floor) Mode is sele cted, air is

distributed to the floor. The foot icon (1) will be

displayed on the LCD screen.

Figure 2F-37

Figure 2F-38

Illumination

PURPOSE OF TEST:

To check the illumination function of the LCD

screen.

PRE-CONDITION:

Engine not running.

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Illumination.

Conduct the Illumination test by pressing the soft

keys on TECH 2 to adjust the illumination level of

the LCD screen. Press the increase soft key on

TECH 2 to increase the illumination level of the

LCD screen. Each press of the soft keys adjusts

the illumination level between 0% and 100% in

10% increments.

Press the decrease soft key on TECH 2 to reduce

the illumination level of the LCD screen.

Press the increase soft key on TECH 2 to raise the

illumination level of the LCD screen.

Continue to press the increase soft key on TECH 2

to maximum illumination level of the LCD screen.

The illumination across the complete LCD screen

should be uniform at any given illumination level.

Figure 2F-39

Figure 2F-40

Figure 2F-41

Figure 2F-42

Front Demist led

PURPOSE OF TEST:

To check the operation of the front demist LED.

PRE-CONDITION:

Engine not running.

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Front Demist LED.

Conduct the Front Demist LED test by pressing the

On soft key to activate the orange LED on the front

demist button. The front demist LED will illuminate.

Use the Off soft key to deactivate the LED.

Figure 2F-43

Figure 2F-44

Rear Demist LED

PURPOSE OF TEST:

To check the operation of the rear demis t LED.

PRE-CONDITION:

Engine not running.

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Rear Demist LED.

Conduct the Rear Demist LED test by p ressin g the

On soft key to activate the orange LED on the rear

demist button. The rear demist LED will illuminate.

Use the Off soft key to deactivate the LED.

Figure 2F-45

Figure 2F-46

Rear Demist Relay

PURPOSE OF TEST:

To check operation of circu i t from OCC control

module to relay.

PRE-CONDITION:

Engine not running.

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Rear Demist Relay.

Figure 2F-47

Conduct the Rear Demist Relay test by pressing the On soft key to activate heated rear window relay. Use

the Off soft key to deactivate relay. The rear demist relay (1) is labelled HEATED REAR WINDOW and is

located in the instrument panel fuse and relay panel (2). Listen or feel for the relay activating (clicking) when

the On and Off soft keys are activated on TECH 2. If the relay does not activate, temporarily substitute with a

serviceable relay from an adjacent installation. If the substitute relay does not activate, refer to Chart A in

2. DIAGNOSTIC CHARTS in this Section.

Figure 2F-48

A/C Request

NOTE 1: In this test a blower fan speed is

automatically selected.

NOTE 2: A three second delay until compressor

clutch engagement will occur. This is a normal

condition.

PURPOSE OF TEST:

To ensure OCC control module, wi ring,

compressor relay and compressor clutch are

functional.

PRE-CONDITION:

Engine running.

PROCEDURE:

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

A/C Request.

Figure 2F-49

Conduct the A/C Request test by using the On soft key to engage the compressor clutch and the Off soft key

to disengage the compressor. Listen fo r clutch engagement noise. If the clutch does not engage, inspect the

A/C compressor relay. The A/C compressor relay (1) is labelled A/C COMPR RELAY and is located in the

engine compartment fuse and relay hou sing (2). Listen or feel for the relay activating (clicking) when the On

and Off soft keys are activated on TECH 2 If the relay does not activate, temporarily substitute with a

serviceable relay from an adjacent installation. If the substitute relay does not activate, refer to Chart A in

2. DIAGNOSTIC CHARTS in this Section.

Figure 2F-50

Solenoids

NOTE: If the TECH 2 Outlet Mode test was carried

out and passed, testing of the mode solenoids

need not be carried out. However, the water valve

solenoid circuit should be tested regardless of

Outlet Mode test results.

PURPOSE OF TEST:

To ensure the OCC control module and the

electrical circuit to the solenoid is OK.

PRE-CONDITION:

Engine not running.

PROCEDURE:

On RHD models remove the left-hand side

instrument panel lower trim plate assembly. On

LHD models remove the right-hand side instrument

panel lower trim plate assembly. Refer to

Section 1A3, 3.1 INSTRUMENT PANEL LOWER

TRIM PLATE ASSEMBLY. Locate the vacuum

solenoid pack (rear of blower motor and fan

housing).

With TECH 2 connected to the DLC select:

Body /

Occupant Climate Control /

Miscellaneous Tests /

Solenoids.

Conduct the Solenoids test by using the On soft

key to activate one solenoid at a time.

Listen or feel for the solenoids activating (clicking).

Use the Off soft key to deactivate solenoids and

likewise listen or feel for solenoids activating

(clicking). If a solenoid or solenoids do not activate,

refer to DTC 41 in 2. DIAGNOSTIC CHARTS in

this Section.

Figure 2F-51

Figure 2F-52

NOTE: The solenoid pack config urations for LHD

and RHD models are not the same. LHD models

use a solenoid pack fitted with five solenoids, refer

to Figure 2F-53. LHD models are also fitted with an

additional remote solenoid for water valve

activation, refer to Figure 2F-54. RHD models use

a solenoid pack fitted with six solenoids that

incorporates the solenoid f or water valve activation,

refer to Figure 2F-55.

Refer to Figure 2F-53, Figure 2F-54 and

Figure 2F-55 to understand which solenoid should

be activated in each mode.

Figure 2F-53 shows the sol enoid outlets from the

LHD HVAC unit vacuum solenoid pack. The

function of the solenoid connections and the colour

of the attached vacuum lines are listed below:

Legend

1. Foot 1 (Red)

2. Defrost (Green)

3. Face 2 (Brown)

4. Face 1 (Blue)

5. Fresh/Recirculation (Yellow)

6. Vacuum Supply (White)

Figure 2F-53

Figure 2F-54 shows the location of the sixth

solenoid for water valve activation on LHD HVAC

units. This electrically operated vacuum switching

valve (1) is located on the front of the HVAC unit

(2). The OCC control module activates the vacuum

switching valve in accordance to a manually

selected, or an automatically controlled

temperature setting.

The water valve is held in the off position by

vacuum. When the a cold setting is selected either

manually or automatically, the vacuum switching

solenoid valve will maintain vacuum to the heater

water valve so that no hot water enters the heater

core.

The integrity of vacuum switching solenoid valve

and its associated circuitry can be asse ssed by

observing the opening and closing action of the

water valve. The water valve is located in the

engine bay on the right-hand side inner guard.

If required, access to the vacuum switching

solenoid valve can achieved by removing the radio

assembly, radio housing and radio bracket

assembly.

Refer to:

• Section 1A3, 3.6 RADIO ASSEMBLY.

• Section 1A3, 3.11 RADIO HOUSING AND

RADIO BRACKET ASSEMBLY.

Figure 2F-54

Figure 2F-55 shows the sol enoid outlets from the

RHD HVAC unit vacuum solenoid pack. The

function of the solenoid connections and the colour

of the attached vacuum lines are listed below:

Legend

1. Fresh/recirculation (Blue)

2. Face 1 (White)

3. Face 2 (Green)

4. Foot 1 (Pink)

5. Foot 2 (Orange)

6. Water valve (Yellow)

7. Vacuum supply (Black)

Figure 2F-55

F5: PROGRAM

In this mode, TECH 2 allows the programming of

the OCC control module.

When the Program option is selected, the following

two choices will be available:

F0: Calibrate Air Mix Door.

F1: Program Code Index.

Figure 2F-56

F0: Calibrate Air Mix Door

In this mode, the air mix doors may be

recalibrated/programmed so they drive to the full

hot and full cold stops.

NOTE: All HVAC units have two air mix doors.

However, their configuration differs according to

application:

• LHD Single Zone – two equally sized doors

operating in unison.

• RHD Single Zone – a large and a small d oor

operating sequentially.

• RHD Dual Zone – two equally sized doors

operating in unison during link mode and

independently during unlink mode.

To understand these configurations refer to

Section 2A, HVAC AIR MIX DOORS and

Section 2D, AIR MIX DOORS AND AIR MIX

MOTORS.

Figure 2F-57

NOTE: During the calibration procedure on singl e zone HVAC units, TECH 2 describes the single air mix door

function as ‘Drivers Air Mix Door’ and not as ‘Air Mix Door’.

The calibration mode looks at the full movement in both directions (open and closed) of the air mix doors/motors

and compares the actual voltage values to known base values. If they are different, the OCC softwa re will

compensate.

Figure 2F-58 shows the air mix door in the closed sta t e. When the air mix door i s clo se d, all air moving through the

HVAC unit has bypassed the heater core, therefore all air entering the cabin is cold.

In this state, the feedback voltage sent back to the OCC control module (by the potentiometer built into the air mix

motor) may be anywhere in the acceptable closed range of 0.4 – 1.3 Volts. This closed range is shown

exaggerated in the magnified view in Figure 2F-58 between points A and B of air mix door movement.

The following summarises the air mix door positions in the closed state:

A: Air mix door fully closed = Cold air ,0.4 Volts = Drivers Minimum Low

B: Air mix door almost fully closed = Cold air ,1.3 Volts = Drivers Minimum Hi gh

Figure 2F-58

Legend

A. Drivers Minimum Low

B. Drivers Minimum High

C. Drivers Minimum Value Achieved (resu lt of previous calibration, i.e. voltage value anywher e between A and B)

D. Drivers Minimum Calibrated Value (result of new calibration, i.e. voltage value anywher e between A and B)

1. HVAC unit 5. Heater Core (Cold – no coolant flow)

2. Blower Fan 6. Cold Air To Cabin

3. Evaporator 7. TECH 2 Calibration Result Screen

4. Air Mix Door

NOTE: During the calibration procedure on singl e zone HVAC units, TECH 2 describes the single air mix door

function as ‘Drivers Air Mix Door’ and not as ‘Air Mix Door’.

Figure 2F-59 shows the air mix door in the open state. When the air mix door is open, all air moving through the

HVAC unit has passed through the heater core, therefore all air entering the cabin will heated air.

In this state, the feedback voltage sent back to the OCC control module (by the potentiometer built into the air mix

motor) may be anywhere in the acceptable open range of 3.3 – 4.7 Volts. This open range is shown exaggerated in

the magnified view in Figure 2F-59 between points A and B of air mix door movement.

The following summarises the air mix door positions in the open state:

A: Air mix door almost fully open = Heated air, 3.3 Volts = Drivers Maximum Low

B: Air mix door fully open = Heated air, 4.7 Volts = Drivers Maximu m High

Figure 2F-59

Legend

A. Drivers Maximum Low

B. Drivers Maximum High

C. Drivers Maximum Value Achieved (result of previous cali brat ion, i.e. voltage value anywhere between A and B)

D. Drivers Maximum Calibrated Value (result of new calibration, i.e. voltage value anywhere between A and B)

1. HVAC unit 5. Heater Core (Hot – coolant flow)

2. Blower Fan 6. Heated Air To Cabin

3. Evaporator 7. TECH 2 Calibration Result Screen

4. Air Mix Door

To calibrate the air mix door, connect TECH 2 to

the DLC and with the engine running, select:

Body /

Occupant Climate Control /

Program /

Calibrate Air Mix Door

Press the Calibrate soft key on TECH 2.

NOTE: Figure 2F-60 shows the calibration screen

applicable to a dual zone system, i.e. specifications

are displayed for the passenger side air mix door

also.

Figure 2F-60

While an air mix door (1) is re calibrating, TECH 2 will display a momentary Calibration Active screen (2) showing

a percentage bar (3) filling from left to right. This symbolises the air mix door being driven from closed (A) to

open (B) and back to closed again.

NOTE: Figure 2F-61 shows the Calibration Active screen applicable to a dual zone system, i.e. specifications

are displayed for the passenger side air mix door also. On a dual zone system, both the driver’s and

passenger’s side air mix door will be calibrated at the same time.

Figure 2F-61

When the air mix doors have been successfully

recalibrated, TECH 2 will display the percentage of

variation between the base value and t he pre-

calibration value. If this variation is greater than

5%, a noticeable difference should be fel t and

could have contributed to a customer complaint.

NOTE 1: If the recalibration programming is

unsuccessful, repeat the program agai n, as the

system may have ‘crashed’ during this pro ce ss.

NOTE 2: During programming, a DTC 47, 48, 49 or

50 could be set. If any of these codes are set, with

TECH 2 connected to the DLC select:

Body /

Occupant Climate /

Diagnostic Trouble Codes /

Clear DTC Information and clear DTC’s.

Figure 2F-62

If the recalibration programming of the air mix door (1) continue s to be unsuccessful, TECH 2 will display a

‘Programming Failed!’ screen (2) as shown in Figure 2F-63. The messag e ‘Driver Error in Maximum Position’ (3 )

defines the problem sector of air mix door movement. This example means that the air mix door (the driver’s

side air mix door on a dual zone system) had difficulty in the maximum (fully open) sector of door movement –

area A.

This may caused by a variety of reasons such as the air mix door fouling within the HVAC case, damaged or

sticking external linkages between the air mix door and air mix motor.

Figure 2F-63

Press the confirm key to view the results of the air

mix door calibration

Figure 2F-64

F1: Program Code Index

In this mode, the Code Index and programmed

Code Version are displayed, as well as providing

the operator the option of reprogramming the code

version of the OCC system to the latest level.

To access the program code index option, select

Body /

Occupant Climate Control /

Program

Figure 2F-65

After the Program option is selected from the Body

menu, the following two choices will be available:

F0: Calibrate Air Mix Door.

F1: Program Code Index.

Select Program Code Index

Figure 2F-66

The Code Index screen will display the current

Code Version (software calibration) loaded into the

OCC module. The Code Version identifies the

programmed level of OCC calibration. A higher

number indicates a later version of calibration

loaded into the OCC module. This calibration can

be updated, if necessary, by using TECH 2.

CODE INDEX DETAILS

Application Index

Single Zone SWB RHD 1

Dual Zone SWB RHD 2

Single Zone SWB LHD 3

The Code Index must match the vehicle type and

OCC system configuration.

To update the calibration press the Modify Soft key

on TECH 2.

A momentary Calibration Active screen will be

displayed on TECH 2 sho wing a p ercentage bar

filling from left to right. This symbolises that

recalibrating of the OCC module is takin g place.

NOTE: If programming is unsuccessful, repeat the

program again, as the reprogramming procedure

may have ‘crashed’ during this proce ss.

Figure 2F-68

After the OCC module has been successfully

reprogrammed, TECH 2 will display a

Programming Completed screen.

Follow any TECH 2 screen prompts when

programming is completed.

Figure 2F-69

2. DIAGNOSTIC CHARTS

INTRODUCTION

The following diagnostic charts are designed to provide fast and efficient fault location of the OCC system. Each

diagnostic chart consists of a diagnostic chart and pertinent information including Diagnostic Trouble Code (DTC)

setting parameters and, in most charts, a circuit diag ram.

At the end of this Section electrical connector diagrams and wiring diagrams applicable to OCC systems as fitted to

MY2003 VY and V2 Series vehicles are provided and can be used in conjunction with the diagnostic chart

circuit diagrams when diagnosing circuit faults. Refer to 5. WIRING DIAGRAMS in this Section. For electrical

connector locations and additional wiring diagram information, refer to Section 12P WIRING DIAGRAMS.

When carrying out wiring checks as directed to by the diagnostic charts, rather than probe terminals and

connectors with incorrect sized multimeter connections, use the adaptors contained in connector test adaptor kit

KM-609. This will prevent any possibility of spreading or damaging wiring harness terminals.

Ensure that at the completion of any diagnostic procedure, all diagnostic tools are removed and all OCC

components are correctly connected.

INTERMITTENTS

Definition: Problems may or may not turn on the X symbol on the OCC module LCD screen or store a DTC,

indicating an intermittent problem. DO NOT use the diagnostic code charts for intermittent problems. When using

the code charts the fault must be present to locate the problem. If a fault is intermittent, use of diagnostic trouble

code charts may result in replacem ent of good parts.

• Most intermittent problems are caused by faulty electrical connections or wiring. Perform careful visual/physical

checks of the applicable circuit.

Check for:

a. Poor mating of the connector halves or a terminal n ot fully seated in the connector body (backed out).

Improperly formed or damaged terminal. All connector terminals in the suspect circuit should be carefully

reformed or replaced to insure proper contact ten sio n.

Poor terminal to wire connection. This requires removing the terminal from the connector body to check as

outlined in service operations.

Loose OCC ground circuit terminals.

• If a visual/physical check does not find the cause of the problem, the car can be driven with a voltmeter

connected to a suspected circuit. A scan tool (TECH 2) can also be used to help detect intermittent conditions.

An abnormal voltage, or scan tool reading, when the problem occurs, indicates the problem may be in that

circuit. If the wiring and connectors check OK, and a diagnostic trouble code was stored for a circuit having a

sensor, substitute a kno wn good sensor and recheck.

• Loss of diagnostic code memory. To check, disconnect Ambient Air Temperature sensor and turn the ignition

on until the X symbol is displayed on LCD screen. DTC 13 should be stored and kept in memory when ignition

is turned off. If not, the OCC module is faulty.

• Check for electrical system interference caused by a defective relay, OCC driven solenoid, or switch. They can

cause a sharp electri cal surge. Normally, the problem will occu r when the faulty component is operated.

• Check for improper in stallation of non-factory installed electrical options such as lights, 2 way radios, etc.

• If problem has not been found, refer to the prope r symptom and perform all checks listed there.

CHART A – DIAGNOSTI C CIR C UIT C HEC K

Circuit Description

When investigating any complaint of an OCC problem or malfunction, always begin diagnosis with the following

diagnostic circuit check. This check is a preliminary procedure that checks to ensure the OCC is communicating on

the serial data line as well as helping to identify a problem or malfunction and directing the reader to the

appropriate diagnostic chart in this Section.

With TECH 2 connected to the DLC and the ignition switched on, TECH 2 should display serial data

communication. If TECH 2 does not display serial data, the serial data circuit may be open or shorted.

In addition to the OCC module there are several other control modules that are connected to the serial data line

(PCM, BCM, ABS/TCS, instruments and SDM). Any one of these control modules could cause a fault on the serial

data line. This fault could result in TECH 2 not being able to displ ay serial d ata.

Test Description:

The numbers below refer to Step numbers in diagnostic chart A.

1. This test checks if the OCC module is being powered up.

2. This test checks if the OCC module has detected and stored a current Diagnostic Trouble Code.

3. This test determines if TECH 2 is being powered up.

4. This test checks if TECH 2 can communicate with the OCC control module. If TECH 2 cannot communicate

with the OCC control module, you will not be able to determine which DTC has been stored in the OCC control

modules memory.

5. Determines which DTC has been stored in the OCC control modules memory. This test determines if a

DTC was current and has been rectified. An intermittent problem will cau se a DT C to be stored.

6. During this test the OCC module recalibrates the air mix doors. An incorrectly calibrated air mix door will cause

incorrect operation of the OCC system.

7. Checks accuracy of OCC sensors.

8. During this test, the operation of the air conditioning section of the OC C system is checked.

Notes On Diagnostic Chart:

1. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

2. Refer to 1.2 TECH 2 TEST MODES AND DISPLAYS FOR OCC DIAGNOSIS in this Section for further

information on programming of the OCC module.

3. OCC sensors can be checked usin g the following procedure and should also be checked in the order listed:

• In-car Temperature Sensor – connect TECH 2 to the DLC, sele ct Body / Occupant Climate Control / Data

Display / Data List / In Car Temperature Sensor.

• Ambient Temperature Sensor – connect TECH 2 to the DLC, select Body / Occupant Climate Control /

Data Display / Data List / Ambient Temperature Sens or.

• Sun Load Sensor (Sun Sensor/Remote Receiver) – refer to DTC 19 diagnostic chart in this Section for a

procedure on checki ng this sensor.

• Evaporative Sensor – connect TECH 2 to the DLC, select Body / Occupant Climate Control / Data Display /

Data List / Evap Temperature Sen sor.

CHART A – DIAGNOSTI C CIR C UIT C HEC K

STEP ACTION VALUE YES NO

1 1. Turn the ignition on.

2. Turn on OCC system.

Does OCC module LCD screen activate?

– Go to Step 2. Go to Chart B –

OCC SYSTEM

DOES NOT

POWER UP in

this Section.

2 Is there an X on the right-hand side of the OCC

module LCD screen? – Go to Step 3. Go to Step 6.

3 1. Connect TECH 2 to the DLC. (Refer to Notes

on Diagnostic Chart for this chart, Note 1.)

2. Turn the ignition on.

3. Push power button on TECH 2.

Does TECH 2 power up?

– Go to Step 4. Go to TECH 2

diagnosis. Refer

to Section 0C,

TECH 2.

4 1. With TECH 2 connected, select Diagnostics /

Model Year / Vehicle Model / Body / Occupant

Climate Control.

Does TECH 2 display OCC System Identification

Screen information (i.e. part number etc.)?

– Go to Step 5. Go to BCM

Serial Data

Communication

diagnostics.

Refer to Section

12J, 4.2 SERIAL

DATA

COMMUNICN

(BUS MASTER).

5 1. With TECH 2 connected and the ignition on,

select Diagnostic Trouble Codes / Read

DTC Information.

Does TECH 2 display any DTCs?

– Go to applicable

DTC Chart in

this Section.

Go to Step 6.

6 1. With TECH 2 connected, the ignition on and

OCC system selected, select Program /

Calibrate Air Mix Door / Calibrate.

Does TECH 2 display a value greater than 5%?

– OCC air mix

doors have

been

recalibrated.

Refer to DTC

48 to DTC 50

as applicable, in

this Section.

7 1. Check the accuracy of the OCC sensors.

(Refer to 3. ELECTRICAL COMPONENT

TESTS in this Section.)

Are the OCC sensors OK?

– Go to Step 8. Replace the

faulty OCC

sensor, refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

8 1. Perform the DELPHI V5 and V7 compressor

and TXV system diagnosis. Refer to

Section 2C, 4. DELPHI V5 AND V7

COMPRESSOR AND TXV SYSTEM

DIAGNOSTICS.

Does the system pass the diagnosis test?

– No fault found

with OCC

system. Syst em

Code Index

may need to be

Programmed.

Refer to

F1:PROGRAM

CODE INDEX

in this Section.

Carry out repair

procedure as

detailed in

Delphi V5 and

V7 Compressor

TXV System

Diagnosis.

Refer to

Section 2C,

HVAC

CLIMATE

CONTROL

(MANUAL A/C)

– SERVICING

& DIAGNOSIS.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

CHART B – OCC SYSTEM DOES NOT POWER UP

Figure 2F-70

Circuit Description

Battery power is supplied to the OCC control module, terminal X1-4, with the ignition switch in the ignition or start

positions through fuse F13 (located in the passe nger compartment fuse panel).

Test Description:

The numbers below refer to Step numbers in diagnostic chart B:

1. The diagnostic circuit test is the beginning of all diagnostics and should be performed whenever diagnosing an

OCC system complaint.

2. This test checks if the fuse F13 is OK.

3. This test determines if power is being supplied to fuse F13.

4. This test determines if the OCC module has a power supply and a ground. If the OCC module has power and

ground and the module is not being activated when the ignition and the OCC system is turned on.

5. If battery voltage was not available during Step 4, this test determines if the power supply circuit 539 to the OCC

module has continuity.

6. If battery voltage was not available during Step 4, this test determines if the ground circuit 251 to the OCC

module has continuity.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

CHART B – OCC SYSTEM DOES NOT POWER UP

STEP ACTION VALUE YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Check f use F13.

Is the fuse OK? – Go to Step 3. Check for cause

of blown fuse

and replace the

fuse.

3 1. Turn the ignition on.

2. Back-probe fuse F13, circuit 3 (Pink wire) with

a voltmeter to ground. (Refer to Notes on

Diagnostic Chart for this chart, Note 1.)

Is the value as specified?

Battery

voltage Go to Step 4. Repair faulty

circuit 3.

4 1. Remove the OCC control module. (Refer to

Section 2E, OCCUPANT CLIMATE CONTROL

(AUTO A/C) REMOVAL AND INSTALLATION.)

2. Turn the ignition on.

3. Probe between OCC module (A14) connector

terminal X1-4, circuit 539 (Pink / Blue wire) and

terminal X1-2, circuit 251 (Black / Yellow wire)

with a voltmeter to ground.

Is the value as specified?

Battery

voltage Replace the

OCC control

module, refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Install the OCC

module (Refer

to Section 2E,

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C)

REMOVAL

AND

INSTALLATION

.) and go to

Step 5.

5 1. Turn the ignition off.

2. Back-probe between OCC module

terminal X1-4, circuit 539 (Pink / Blue wire) and

fuse F13 with an ohmmeter to ground.

Is the value as specified?

Less than

1 ohm Go to Step 6. Repair faulty

circuit 539.

6 1. Turn the ignition off.

2. Back-probe OCC module terminal X1-2,

circuit 251 (Black / Yellow wire) with an

ohmmeter to a known good ground.

Is the value as specified?

Less than

1 ohm Check for

intermittent

connection at

OCC module

connector

A14 X1. Check

sizing of

connector

A14 X1

terminals.

Repair faulty

circuit 251.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 13 – AMBIENT TEMPERAT URE SENSOR VOLTAGE TOO HIGH

Figure 2F-71

Circuit Description:

The Ambient Temperature Sensor (ATS) uses a thermistor to control the signal voltage to the OCC control module.

The OCC module applies a voltage of 5.0 volts to the sensor. When the air is cold, the ATS resistance is high,

therefore the OCC module will sense a high signal voltage. If the ambient air is warm, the ATS resistance is low

therefore the OCC module will sense a low signal voltage.

DTC 13 will set if: the ATS sensor signal voltage is more than 5.0 volts or if the ATS sensor wiring harness

(circuit 735) or connectors are op en circuited for a period of 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. Checks that the conditions for setting the DTC are present or if fault is intermittent.

3. Checks integrity of circuit 735.

4. Checks if sensor is service able by t e st ing resistance across ATS.

5. Checks for an intermittent connection at ATS.

6. Checks for an open in circuit 251.

7. Checks for an open in circuit 735.

8. Checks for short to voltage in circuit 735.

Diagnostic Aids:

The default temperature for an open circuit is 22.5°C.

If the vehicle is left idling for an extended period, the ambient temperature readings will rise owing to heat radiated

by the A/C condenser and lack of airflow.

When using the temperature/resistance chart, place a thermometer as close as possible to the sensor being tested,

then compare this temperature figure to the resistance value.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

Temperature Resistance Chart

AMBIENT°C RESISTANCE Ω

0 15920 – 16750

10 9715 – 10193

20 6107 – 6389

30 3943 – 4115

40 2610 – 2717

50 1767 – 1836

60 1201 – 1291

DTC 13 – AMBIENT TEMPERATURE SENSOR VOLTAGE TOO HIGH DIAGN OSTIC CHART

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC.

2. Select Diagnostics / Model Year / Vehicle

Model / Body / Occupant Climate Control /

Data Display / Data List / Ambient Air

Temperature Sensor.

Does TECH 2 display a value above 4.8 volts?

– Go to Step 3. DTC 13

intermittent. If

no additional

DTCs were

stored. Refer to

2. DIAGNOSTI

C CHARTS in

this Section.

3 1. With TECH 2 connected and Ambient Air

Temperature Sensor displayed, disconnect the

ambient air temperature sensor wiring harness

connector B23 X1.

2. Place a jumper wire between the two terminals

of connector B23 X1.

Does TECH 2 display a value less than 0.4 volt?

– Go to Step 4. Go to Step 6

4 1. With the ambient air temperature sensor wiring

harness connector disconnected, probe

between the ambient air sensor terminals with

an ohmmeter to ground.

Is the value as specified?

Refer to

DTC 13

Temp.

Resistance

Chart

outlined

previously.

Go to Step 5. Replace faulty

ambient air

temperature

sensor. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C)–

REMOVAL &

INSTALLATION

5 1. Inspect the ambient air temperature sensor

wiring harness connector for an intermittent or

loose terminal.

Is connector OK?

– Go to Step 8 Repair faulty

connector.

6 1. With TECH 2 connected and Ambient Air

Temperature Sensor displayed, back-probe

between OCC module connector

terminal X1-12, circuit 735 (Light-green / Black

wire) and chassis ground with a jumper lead.

Does TECH 2 display a value less than 0.4 volt?

– Repair faulty

circuit 251

(Black / Yellow

wire).

Go to Step 7

7 1. Check the integrity of circuit 735 (Light-green /

Black wire) between ambient air temperature

sensor connector terminal X1-B and OCC

module connector terminal X1-12.

Is the circuit OK?

– Go to Step 8 Repair faulty

circuit 735.

8 1. Turn the ignition off.

2. Disconnect OCC wiring harness connectors

A14 X1 and A14 X2.

3. Remove the jumper lead from the ambient air

temperature sensor connector.

4. Turn the ignition on.

5. Back-probe ambient air temperature sensor

wiring harness connector terminal X1-B

circuit 735 (Light-green / Black wire) with a

voltmeter to chassis ground.

Is the value as specified?

0.4 volt Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit 735.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 14 – AMBIENT TEMPERAT URE SENSOR VOLTAGE TOO LOW

Figure 2F-72

Circuit Description:

The ambient air temperature sensor (ATS) uses a thermistor to control the signal voltage to the OCC control

module. The OCC module applies a voltage of 5.0 volts to the sensor. When the air is cold, the ATS resistance is

high therefore the OCC module will sense a high signal voltage. If the air is warm, the ATS resistance is low

therefore the OCC module will sense a low signal voltage.

DTC 14 will set: if the ATS sensor signal voltage is less than 0.3 volt or if the ATS sensor wiring harness

(circuit 735) or connectors are op en for a period of 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the conditions that would set the DTC, are p resent.

3. This test checks if the sensor is causing the sho rt circuit.

4. This test checks if sensor is functioning correctly.

5. Checks for intermittent connection at sensor.

6. Checks for a short circuit of sensor signal wire to ground.

Diagnostic Aids:

The default temperature for a short circuit is 22.5° C.

If the vehicle is left idling for an extended period, the ambient temperature readings will rise owing to heat radiated

by the A/C condenser and lack of airflow.

When using the temperature/resistance chart, place a thermometer as close as possible to the sensor being tested,

then compare this temperature figure to the resistance value.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

Temperature Resistance Chart

AMBIENT°C RESISTANCE Ω

0 15920 – 16750

10 9715 – 10193

20 6107 – 6389

30 3943 – 4115

40 2610 – 2717

50 1767 – 1836

60 1201 – 1291

DTC 14 – AMBIENT TEMPERATURE SENSOR VOLTAGE TOO LOW DI AGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC.

2. Select Diagnostics / Model Year / Vehicle

Model / Body / Occupant Climate Control /

Data Display / Data List / Ambient Air

Temperature Sensor.

Does TECH 2 display a value less than 0.4 volt?

– Go to Step 3. DTC 14

intermittent. If

no additional

DTCs were

stored, refer to

2. DIAGNOSTI

C CHARTS in

this Section.

3 1. With TECH 2 connected and Ambient Air

Temperature Sensor displayed, disconnect

ambient air temperature sensor wiring harness

connector B23 X1.

Does TECH 2 display a value more than 4.8 volts?

– Go to Step 4. Go to Step 6.

4 1. With the ambient air temperature sensor wiring

harness connector disconnected, back-probe

between the ambient air sensor terminals.

Is the value as specified?

Refer to

DTC 14

Temp.

Resistance

Chart.

Go to Step 5. Replace the

faulty ambient air

temperature

sensor. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

5 1. Check for an intermittent short to ground in

circuit 735 (Light-green / Black wire) between

OCC module connector terminal X1-12 and

ambient air sensor connector terminal X1-B.

Is the circuit OK?

– Repair faulty

connector. Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

6 1. Check circuit 735 (Light-green / Black wire) for

a short circuit to ground.

Is the circuit OK?

– Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit 735.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 15 – IN-CAR TEMPERATU RE SENSOR VO LTAGE TOO HIGH

Figure 2F-73

Circuit Description:

The In-car Temperature Sensor (ITS) is a thermistor used to vary voltage signals to control the signal voltage to the

OCC control module. The OCC module applies a voltage of 5.0 volts to the sensor, via circuit 734. When the

vehicle interior air is cold, the ITS resistance is high therefore the OCC module will sense a high signal voltage. If

the air is warm, the ITS resistance is low, therefore the OCC module will sense a low signal voltage.

DTC 15 will set: if the ITS signal voltage is more than 4.8 volts or if the ITS sensor wiring harness (circuit 734) or

connectors are open circuited for 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. Checks that the conditions for setting the DTC are present or if fault is intermittent.

3. Checks integrity of circuit 734.

4. Checks if sensor is service able by t e st ing resistance across ITS.

5. Checks for an intermittent connection at ITS.

6. Checks for an open in circuit 251.

7. Checks for an open in circuit 734.

8. Checks for short to voltage in circuit 734.

Diagnostic Aids:

The default temperature for an open circuit is 22.5°C.

When using the temperature/resistance chart, place a thermometer as close as possible to the sensor being tested,

then compare this temperature figure to the resistance value.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

Temperature Resistance Chart

AMBIENT°C RESISTANCE Ω

5 7009 – 7536

10 5477 – 5856

15 4310 – 4583

20 3416 – 3612

25 2725 – 2865

30 2175 – 2299

35 1746 – 1857

40 1410 – 1508

45 1145 – 1231

50 935 – 1010

DTC 15 – IN-CAR TEMPERATURE SENSOR VOLTAGE TOO HIGH DIAGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC (refer to Note 2

on previous page).

2. Select Diagnostics / Model Year / Vehicle

Model / Body / Occupant Climate Control /

Data Display / Data List / In-car Temperature

Sensor.

Does TECH 2 display a value above 4.8 volts?

– Go to Step 3. DTC 15

intermittent. If

no additional

DTCs were

stored, refer to

2. DAGNOSTIC

CHARTS in this

Section.

3 1. With TECH 2 connected and In-car

Temperature Sensor displayed, disconnect the

in-car temperature sensor wiring harness

connector B59 X1.

2. Probe between the two terminals of the

connector with a jumper wire.

Does TECH 2 display a value less than 0.4 volt?

– Go to Step 4. Go to Step 6.

4 1. With the in-car temperature sensor wiring

harness connector disconnected, probe

between the two terminals of the connector

with an ohmmeter. (Refer to Notes on

Diagnostic Chart for this chart, Note 1).

Is the value as specified?

Refer to

DTC 15

Temp.

Resistance

Chart.

Go to Step 5. Replace faulty

in-car

temperature

sensor. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

5 1. Inspect the in-car temperature sensor wiring

harness connector for an intermittent or loose

terminal.

Is the connector OK?

– Go to Step 8. Repair faulty

connector.

6 1. With TECH 2 connected and In-car

Temperature Sensor displayed, back-probe

OCC connector terminal X1-10, circuit 734

(Blue/Black wire) with a jumper lead to chassis

ground.

Does TECH 2 display a value less than 0.4 volt?

– Go to Step 7. Repair faulty

circuit 251.

7 1. Check the integrity of circuit 734 (Blue/Black

wire) between the OCC module connector and

in car temperature sensor connector. (Refer to

Notes on Diagnostic Chart for this chart, Note

1.)

Is the circuit OK?

– Go to Step 8. Repair faulty

circuit 734.

8 1. Turn the ignition OFF.

2. Disconnect the OCC module wiring harness

connectors A14 X1 and A14 X2.

3. Remove jumper lead from the in-car

temperature sensor connector.

4. Turn the ignition on.

5. Back-probe in-car temperature sensor wiring

harness connector terminal X1-A, circuit 734

(Blue/Black wire) with a voltmeter to chassis

ground.

Is the value as specified?

Less than

0.4 volt Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit 734.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 16 – IN-CAR TEMPERATU RE SENSOR VO LTAGE TOO LOW

Figure 2F-74

Circuit Description:

The in-car temperature sensor (ITS) is a thermistor used to vary voltage signals to the OCC control module. The

OCC module applies a voltage of 5.0 volts to the sensor. When the vehicle interior air is cold, the ITS resistance is

high, therefore the OCC module will sense a high signal voltage. If the air is warm, the ITS resistance is low,

therefore the OCC module will sense a low signal voltage.

DTC 16 will set: if the ITS signal voltage is less than 0.3 volt or if the ITS sensor wiring harness (circuit 734) or

connectors are open circuited for 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the conditions that would set the DTC, are p resent.

3. This test checks if the sensor is causing the sho rt circuit.

4. This test checks if sensor is functioning correctly.

5. Checks for intermittent connection at sensor.

6. Checks for a short circuit of sensor signal wire to ground.

Diagnostic Aids:

The default temperature for a short circuit is 22.5°C.

When using the temperature/resistance chart, place a thermometer as close as possible to the sensor being tested,

then compare this temperature figure to the resistance value.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

Temperature Resistance Chart

AMBIENT°C RESISTANCE Ω

5 7009 – 7536

10 5477 – 5856

15 4310 – 4583

20 3416 – 3612

25 2725 – 2865

30 2175 – 2299

35 1746 – 1857

40 1410 – 1508

45 1145 – 1231

50 935 – 1010

DTC 16 – IN-CAR TEMPERATURE SENSOR VOLTAGE TOO LOW DIAG NOSTIC CHART

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC.

2. Select Diagnostics / Model Year / Vehicle

Model / Body / Occupant Climate Control /

Data Display / Data List / In-car Temperature

Sensor.

Does TECH 2 display a value less than 0.4 volt?

– Go to Step 3. DTC 16

intermittent. If

no additional

DTCs were

stored, refer to

2. DIAGNOSTI

C CHARTS in

this Section.

3 1. With TECH 2 connected and In-car

Temperature Sensor displayed, disconnect the

in-car temperature sensor wiring harness

connector B59 X1.

Does TECH 2 display a value above 4.8 volts?

– Go to Step 4. Go to Step 6.

4 1. With the in-car temperature sensor wiring

harness connector disconnected, probe

between the in-car sensor terminals with an

ohmmeter. (Refer to Notes on Diagnostic Chart

for this chart, Note 1.)

Is the value as specified?

Refer to

DTC 16

Temp.

Resistance

Chart.

Go to Step 5. Replace the

faulty in-car

temperature

sensor. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

5 1. Check the in-car temperature sensor

connectors B59 X1 and A14 X1, circuit 734

(Blue / Black wire) for an intermittent short to

ground. (Refer to Notes on Diagnostic Chart

for this chart, Note 1.).

– Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

connector.

6 1. Check the integrity of circuit 734 (Blue / Black

wire). (Refer to Notes on Diagnostic Chart for

this chart, Note 1.).

Is the circuit OK?

– Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit 734.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 17 – EVAPORATIVE TEMPERATURE SENSOR VOLTAGE TOO HIGH (LHD)

Figure 2F-75

Circuit Description:

The Evaporative Temperature Sensor (ETS) uses a thermistor to vary voltage signals to the OCC control module.

The OCC module applies a voltage of 5.0 volts to the sensor. When the air is cold, the ETS resistance is high,

therefore the OCC module will sense a high signal voltage. If the air is warm the resistance is low, therefore the

OCC module will sense a low signal voltage.

DTC 17 will set if the ETS signal voltage is more than 4.8 volts or if the ETS sensor wiring harness (circuit 2210) or

connectors are open circuited for 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the conditions that would set the DTC, are p resent.

3. This test checks if the wiring or sensor is open circuit.

4. This test checks if wiring is shorted to the ignition feed in the OCC harness.

5. This test checks if wiring is shorted to the 5.0 V feed in the OCC harness.

6. This test checks if wiring is shorted to a voltage in the main wiring harne ss.

7. Check for intermittent connection at OCC.

8. This test checks if sensor is functioning correctly.

9. Check for intermittent connection at sensor.

10. This test checks for an open circuit sensor g ro und wire.

11. This test checks for an open circuit sensor signal wire.

Diagnostic Aids:

The default temperature for an open circuit is 5°C.

When using the temperature/resistance chart, place a thermometer in the centre vent, set temperature to full cold

and manual fan speed to 2. This will give an approximate evaporative air temperature. Compare this temperature

to the chart.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

Temperature Resistance Chart

AMBIENT°C RESISTANCE Ω

5 4300 – 4850

10 3600 – 4050

15 2950 – 3250

20 2320 – 2625

25 1990 – 2200

30 1675 – 1850

35 1330 –1470

40 1140 – 1260

45 950 – 1050

50 850 - 950

DTC 17 – EVAPORATIVE TEMPERATURE SENSOR VOLTAGE TOO HIGH DIAGNOSTIC CHART (LHD)

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC.

2. Select Diagnostics / Model Year / Vehicle

Model / Body / Occupant Climate Control /

Data Display / Data List / Evap Temperature

Sensor.

Does TECH 2 display a value above 4.8 volts?

– Go to Step 3. DTC 17 is

intermittent. If

no other DTCs

are stored, refer

2. DIAGNOSTI

C CHARTS in

this Section.

3 1. Disconnect OCC connector A14 X2.

2. Probe between OCC evaporative air

temperature sensor (ETS) terminals X2-19 and

X2-15 with an ohmmeter. (Refer to Notes on

Diagnostic Chart for this chart, Note 1).

Is the value as specified?

Refer to

Temp.

Resistance

Chart.

Go to Step 4. Go to Step 8.

4 1. With the OCC connector A14 X2 disconnected,

probe between OCC harness connector

terminals X2-5, circuit 274 (Red / White wire)

and X2-19, circuit 2210 (White / Black wire)

with an ohmmeter.

Does a short exist?

NOTE: Any resistance measured here qualifies as

a short

– Repair faulty

circuits 274 and

/ or 2210.

Verify repair.

Go to Step 5.

5 1. With the OCC connector A14 X2 disconnected,

probe between OCC harness connector

terminal X2-11, circuit 705 (White wire) and

connector terminal X2-19, circuit 2210 (White /

Black wire).

Is the value as specified?

Less than

4,000 Ω Repair faulty

circuits 705 and

2210.

Verify repair.

Go to Step 6.

6 1. Turn the ignition on.

2. Back-probe OCC harness connector

terminal X2-19, circuit 2210 (White / Black

wire) with a voltmeter to chassis g round.

Is the value as specified?

Less than

0.4 volt Go to Step 7. Repair faulty

circuit 2210.

7 1. Inspect the OCC harness connector A14 X2 for

an intermittent or loose terminal.

Is the connector OK?

– Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

connector

A14 X2.

STEP ACTION VALUE YES NO

8 1. Disconnect ETS connector B34 X1. Refer to

Temp.

Resistance

Chart.

Go to Step 9. Replace the

faulty

evaporative

temperature

sensor. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

9 1. Inspect the evaporative air temperature sensor

harness connector B34 X1 for an intermittent

or loose terminal.

Is the connector OK?

– Go to Step 10. Repair faulty

connector

B34 X1.

10 1. Check the integrity of circuit 61 (White wire)

between (B34) connector terminal X1-2 and

(A14) connector terminal X2-15. (Refer to

Notes on Diagnostic Chart for this chart, Note

1.)

Is the circuit OK?

– Go to Step 11. Repair faulty

circuit 61.

11 1. Check the integrity of circuit 2210 (White /

Black wire) between (B34) connector

terminal X1-1 and (A14) connector

terminal X2-19.

Is the circuit OK?

– Reconnect

evaporative air

temp sensor

harness

connector

B34 X1 and go

to Step 4.

Repair faulty

circuit 2210.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 17 – EVAPORATIVE TEMPERATURE SENSOR VOLTAGE TOO HIGH (RHD)

Figure 2F-76

Circuit Description:

The Evaporative Temperature Sensor (ETS) uses a thermistor to vary voltage signals to the OCC control module.

The OCC module applies a voltage of 5.0 volts to the sensor. When the air is cold, the ETS resistance is high,

therefore the OCC module will sense a high signal voltage. If the air is warm the resistance is low, therefore the

OCC module will sense a low signal voltage.

DTC 17 will set: if the ETS signal voltage is more than 4.8 volts or if the ETS sensor wiring harness (circuit 2210) or

connectors are open circuited for 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the conditions that would set the DTC, are p resent.

3. This test checks if the wiring or sensor is open circuit.

4. This test checks if wiring is shorted to the ignition feed in the OCC harness.

5. This test checks if wiring is shorted to the 5.0 V feed in the OCC harness.

6. This test checks if wiring is shorted to a voltage in the main wiring harne ss.

7. Check for intermittent connection at OCC.

8. This test checks if sensor is functioning correctly.

9. Check for intermittent connection at sensor.

10. This test checks for an open circuit sensor g ro und wire.

11. This test checks for an open circuit sensor signal wire.

Diagnostic Aids:

The default temperature for an open circuit is 5°C.

When using the temperature/resistance chart, place a thermometer in the centre vent, set temperature to full cold

and manual fan speed to 2. This will give an approximate evaporative air temperature figure. Compare this to the

chart.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

Temperature Resistance Chart

AMBIENT°C RESISTANCE Ω

5 4300 – 4850

10 3600 – 4050

15 2950 – 3250

20 2320 – 2625

25 1990 – 2200

30 1675 – 1850

35 1330 –1470

40 1140 – 1260

45 950 – 1050

50 850 - 950

DTC 17 – EVAPORATIVE TEMPERATURE SENSOR VOLTAGE TOO HIGH DIAGNOSTIC CHART (RHD)

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC.

2. Select Diagnostics / Model Year / Vehicle Model

/ Body / Occupant Climate Control / Data

Display / Data List / Evap Temperature Sensor.

Does TECH 2 display a value above 4.8 volts?

– Go to Step 3. DTC 17 is

intermittent. If

no other DTCs

are stored, refer

2. DIAGNOSTI

C CHARTS in

this Section.

3 1. Disconnect O CC connector A14 X2.

2. Probe between OCC evaporative air

temperature sensor (ETS) terminals X2-19 and

X2-15 with an ohmmeter. (Refer to Notes on

Diagnostic Chart for this chart, Note 1.)

Is the value as specified?

Refer to

Temp.

Resistance

Chart.

Go to Step 4. Go to Step 8.

4 1. With the OCC connector A14 X2 disconnected,

probe between OCC harness connector

terminals X2-5, circuit 274 (Red / White wire)

and X2-19, circuit 2210 (White / Black wire) with

an ohmmeter.

Does a short exist?

NOTE: Any resistance measured here qualifies as a

short

– Repair faulty

circuits 274 and

/ or 2210.

Go to Step 5.

5 1. With the OCC connector A14 X2 disconnected,

probe between OCC harness connector

terminal X2-11, circuit 705 (White wire) and

connector terminal X2-19, circuit 2210 (White /

Black wire).

Is the value as specified?

Less than

4,000 Ω Repair faulty

circuits 705 and

2210.

Go to Step 6.

6 1. Turn the ignition on.

2. Back-probe OCC harness connector

terminal X2-19, circuit 2210 (White / Black wire)

with a voltmeter to chassis ground.

Is the value as specified?

Less than

0.4 volt Go to Step 7. Repair faulty

circuit 2210.

STEP ACTION VALUE YES NO

7 1. Inspect the OCC harness connector A14 X2 for

an intermittent or loose terminal. – Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

connector

A14 X2.

8 1. Disconnect ETS connector B34 X1.

2. Probe between the evaporative air temperature

sensor terminals with an ohmmeter. (Refer to

Notes on Diagnostic Chart for this chart, Note

1).

Is the value as specified?

Refer to

Temp.

Resistance

Chart.

Go to Step 9. Replace the

faulty

evaporative

temperature

sensor. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

9 1. Inspect the evaporative air temperature sensor

harness connector B34 X1 for an intermittent or

loose terminal.

Is the connector OK?

– Go to Step 10. Repair faulty

connector

B34 X1.

10 1. Check the integrity of circuit 61 (Tan wire)

between (B34) connector terminal X1-B and

(A14) connector terminal X2-15. (Refer to Notes

on Diagnostic Chart for this chart, Note 1.)

Is the circuit OK?

– Go to Step 11. Repair faulty

circuit 61.

11 1. Check the integrity of circuit 2210 (White / Black

wire) between (B34) connector terminal X1-A

and (A14) connector terminal X2-19.

Is the circuit OK?

– Reconnect

evaporative air

temp sensor

harness

connector

B34 X1 and go

to Step 4.

Repair faulty

circuit 2210.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 18 – EVAPORATIVE TEMPERATURE SENSOR VOLTAGE TOO LOW (LHD)

Figure 2F-77

Circuit Description:

The evaporative temperature sensor (ETS) uses a thermistor to control the signal voltage to the OCC control

module. The OCC module applies a voltage of 5.0 volts to the sensor. When the air off the evaporator core is cold,

the ETS resistance is high, therefore the OCC module will sense a high signal voltage. If the air is warm, the ETS

resistance is low, therefore the OCC mod ule will sense a low signal voltage.

DTC 18 will set if the ETS signal voltage is less than 0.3 volt or if the ETS sensor wiring harness (circuit 2210) or

connectors are open circuited for 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the conditions that would set the DTC, are p resent.

3. This test checks if the sensor or wiring is causing the short circuit.

4. This test checks if sensor and wi ring is functioning correctly.

5. Check for intermittent connectio n at sensor

6. This test checks for a short circuit of the sen sor signal wire to ground.

7. This test determines if the sensor is shorted or the wire is sh orted.

Diagnostic Aids:

The default temperature for a short circuit is 5°C.

When using the temperature/resistance chart, place a thermometer in the centre vent, set temperature to full cold

and manual fan speed to 2. This will give an approximate evaporative air temperature figure. Compare this to the

chart.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

Temperature Resistance Chart

AMBIENT°C RESISTANCE Ω

5 4300 – 4850

10 3600 – 4050

15 2950 – 3250

20 2320 – 2625

25 1990 – 2200

30 1675 – 1850

35 1330 – 1470

40 1140 – 1260

45 950 – 1050

50 850 – 950

DTC 18 – EVAPORATIVE TEMPERATURE SENSOR VOLTAGE TOO LOW DIAGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC (Refer to Notes

on Diagnostic Chart for this chart, Note 2.)

2. Select Diagnostics / Model Year / Vehicle

Model / Body / Occupant Climate Control /

Data Display / Data List / Evap Temperature

Sensor.

Does TECH 2 display a value less than 0.4 volt?

– Go to Step 3. DTC 18

intermittent. If

no other DTCs

are stored, refer

2. DIAGNOSTI

C CHARTS in

this Section

3 1. With TECH 2 connected and Evap

Temperature Sensor displayed, disconnect the

OCC wiring harness A14 X2.

Does TECH 2 display a value above 4.8 volts?

– Go to Step 4. Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

4 1. With the OCC connector A14 X2 disconnected,

probe between the OCC connector terminals

X2-19 and X2-15 with an ohmmeter. (Refer to

Notes on Diagnostic Chart for this chart, Note

1.)

Is the value as specified?

Refer to

Temp.

Resistance

Chart.

Go to Step 5. Go to Step 7

5 1. With the OCC connector A14 X2 disconnected,

probe OCC harness connector terminal X2-19,

circuit 2210 (White/ Black wire) with an

ohmmeter to ground.

Is the value as specified?

More than

0 ohm Repair faulty

circuit 2210. Go to Step 6

6 1. Inspect the OCC and evaporative air

temperature sensor wiring harness and

connectors B34 X1 and A14 X2 for an

intermittent short.

Are the circuits OK?

– Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuits /

connectors as

necessary.

7 1. Disconnect the evaporative temperature

sensor connector B24 X1.

2. Install OCC connectors A14 X1 and A14 X2.

3. With TECH 2 connected, select Body /

Occupant Climate Control / Data Display / Data

List / Evap Temperature Sensor.

Does TECH 2 display a value above 3.4 volts?

– Replace the

faulty

evaporative

temperature

sensor. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit 2210.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 18 – EVAPORATIVE TEMPERATURE SENSOR VOLTAGE TOO LOW (RHD )

Figure 2F-78

Circuit Description:

The evaporative temperature sensor (ETS) uses a thermistor to control the signal voltage to the OCC control

module. The OCC module applies a voltage of 5.0 volts to the sensor. When the air off the evaporator core is cold,

the ETS resistance is high, therefore the OCC module will sense a high signal voltage. If the air is warm, the ETS

resistance is low, therefore the OCC mod ule will sense a low signal voltage.

DTC 18 will set: if the ETS signal voltage is less than 0.3 volt or if the ETS sensor wiring harness (circuit 2210) or

connectors are open circuited for 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the conditions that would set the DTC, are p resent.

3. This test checks if the sensor or wiring is causing the short circuit.

4. This test checks if sensor and wi ring is functioning correctly.

5. Check for intermittent connection at sensor.

6. This test checks for a short circuit of the sen sor signal wire to ground.

7. This test determines if the sensor is shorted or the wire is shorted.

Diagnostic Aids:

The default temperature for a short circuit is 5°C.

When using the temperature/resistance chart, place a thermometer in the centre vent, set temperature to full cold

and manual fan speed to 2. This will give an approximate evaporative air temperature figure. Compare this to the

chart.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAGNOSTICS in this Sectio n for connecting and using TECH 2.

Temperature Resistance Chart

AMBIENT°C RESISTANCE Ω

5 4300 – 4850

10 3600 – 4050

15 2950 – 3250

20 2320 – 2625

25 1990 – 2200

30 1675 – 1850

35 1330 – 1470

40 1140 – 1260

45 950 – 1050

50 850 – 950

DTC 18 – EVAPORATIVE TEMPERATURE SENSOR VOLTAGE TOO LOW DIAG NOSTIC CHART (RHD)

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC (Refer to Notes

on Diagnostic Chart for this chart, Note 2.)

2. Select Diagnostics / Model Year / Vehicle

Model / Body / Occupant Climate Control /

Data Display / Data List / Evap Temperature

Sensor.

Does TECH 2 display a value less than 0.4 volt?

– Go to Step 3. DTC 18

intermittent. If

no other DTCs

are stored, refer

2. DIAGNOSTI

C CHARTS in

this Section

3 1. With TECH 2 connected and Evap

Temperature Sensor displayed, disconnect the

OCC wiring harness A14 X2.

Does TECH 2 display a value above 4.8 volts?

– Go to Step 4. Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

4 1. With the OCC connector A14 X2 disconnected,

probe between the OCC connector terminals

X2-19 and X2-15 with an ohmmeter. (Refer to

Notes on Diagnostic Chart for this chart, Note

1.)

Is the value as specified?

Refer to

Temp.

Resistance

Chart.

Go to Step 5. Go to Step 7

5 1. With the OCC connector A14 X2 disconnected,

probe OCC harness connector terminal X2-19,

circuit 2210 (White/ Black wire) with an

ohmmeter to ground.

Is the value as specified?

More than

0 ohm Repair faulty

circuit 2210. Go to Step 6

6 1. Inspect the OCC and evaporative air

temperature sensor wiring harness and

connectors B34 X1 and A14 X2 for an

intermittent short.

Are the circuits OK?

– Replace the

faulty OCC

control module.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuits /

connectors as

necessary.

7 1. Disconnect the evaporative temperature

sensor connector B24 X1.

2. Install OCC connectors A14 X1 and A14 X2.

3. With TECH 2 connected, select Body /

Occupant Climate Control / Data Display / Data

List / Evap Temperature Sensor.

Does TECH 2 display a value above 3.4 volts?

– Replace the

faulty

evaporative

temperature

sensor. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit 2210.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 19 – SUN LOAD SENSOR ERROR

Figure 2F-79

Circuit Description:

The sun load sensor is mounted in the instrument panel pad between the demist ducts to monitor the amount of

sun load and ambient light in front of the vehicle. The ambient light monitored is used by the BCM for Auto Lights

On operation (twilight sentinel) and the sun load monitored is used by the OCC control module. The BCM monitors

the voltage from this sensor via circuit 1784 and converts this voltage signal into Steps which it sends to the OCC

module via the auxiliary serial data line, circuit 1061. The message sent will vary between 0 and 254 Steps,

depending on the amount of sun load (0 = no sun load, 254 = maximum sun load).

DTC 19 will set if the BCM sends a sun load sensor value of 255 Steps to the OCC module for 10 seconds. The

BCM will send this value if it detects a high sun load and a low twilight level.

NOTE: This trouble code is for information only; under no circumstances should the OCC module be replaced due

to this trouble code.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2 & 3. Uses TECH 2 to check ambient light level data on the auxiliary serial data bus.

4 & 5. Uses TECH 2 to check ambient light level signal at microprocessor of BCM.

6. Determines if the sun sensor / remote receiver module has power and ground by checking operation of the

remote coded key reader.

7 & 8. Checks ambient light level signal at input to BCM.

9. Checks integrity of circuit 1784 (open, sh ort to ground or short to Battery voltage).

10. Checks battery voltage supply at sun sensor / remote receiver module.

11. Checks integrity of circuit 219 (open, sh ort to ground or short to Battery voltage).

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

2. For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS.

3. Refer to 1.1 TECH 2 DIAG NOSTICS in this Section for connecting and u sing TECH 2.

DTC 19 – SUN LOAD SENSOR ERROR DIAGNOS TIC C HA RT

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC.

2. Select Diagnostics / Model Year / Vehicle

Model / Body / Body Control Module / Normal

Mode / Ambient Light Level.

3. Cover the sun load sensor / remote receiver

module assembly.

Does TECH 2 display 1 Step?

– Uncover the

sun load sensor

/ remote

receiver module

assembly and

go to Step 3.

Go to Step 4.

3 1. With TECH 2 connected and the Ambient Light

Level displayed, shine a torch directly on the

sun load sensor / remote receiver module

assembly.

Does TECH 2 display 254 Step?

– Fault not found,

if no other

DTCs are

stored, refer to

2. DIAGNOSTI

C CHARTS in

this Section.

Go to Step 4.

4 1. With the sun load sensor / remote receiver

module assembly covered and TECH 2

connected, select Body / Body Control Module

/ Data Display / Data List / Ambient Light

Sensor display.

Does TECH 2 display less than 0.5 volts?

– Replace the

BCM. Refer to

Section 12J, 2.1

BODY

CONTROL

MODULE.

Go to Step 5.

5 1. With TECH 2 connected and the Ambient Light

Sensor displayed, shine a torch on the sun

load sensor / remote receiver module

assembly.

Does TECH 2 display approximately 5 volts?

– Replace the

BCM. Refer to

Section 12J, 2.1

BODY

CONTROL

MODULE.

Go to Step 6.

6 1. Check the operation of the remote coded key

receiver by locking and unlocking the doors

using the remote coded key (Lock and Unlock

buttons).

Does remote coded key re ceiver operate?

– Go to Step 7. Go to Step 10.

7 1. Back-probe BCM connector terminal X2-2,

circuit 1784 (Yellow / Black wire) with a

voltmeter to ground. (Refer to Notes on

Diagnostic Chart for this chart, Note 1.)

2. Turn the ignition on.

3. Cover the sun load sensor / remote receiver

module assembly.

Is the value as specified?

Less than

0.5 volt Replace BCM.

Refer to Section

12J, 2.1 BODY

CONTROL

MODULE.

Go to Step 8.

8 1. Back-probe BCM connector terminal X2-2,

circuit 1784 (Yellow / Black wire) with a

voltmeter to ground.

2. Turn the ignition on.

3. Shine a torch on the sun load sensor / remote

receiver module assembly.

Is the value as specified?

Approx.

5 volts Replace the

BCM. Refer to

Section 12J, 2.1

BODY

CONTROL

MODULE.

Go to Step 9.

STEP ACTION VALUE YES NO

9 1. Check the integrity of circuit 1784 (Yellow /

Black wire). – Replace the sun

sensor / remote

receiver

module. Refer

to Section 12J,

2.1 BODY

CONTROL

MODULE.

Repair faulty

circuit 1784.

10 1. Back-probe sun sensor / remote receiver

module connector terminal X1-6, circuit 740

(Orange / Black wire) with a voltmeter to

ground.

Is the value as specified?

12 volts Go to Step 11. Repair faulty

circuit 740.

11 1. Check the integrity of circuit 219

(Brown/Green wire).

Is the circuit OK?

– Go to Step 7. Repair faulty

circuit 219.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 35 – NO SERIAL DATA FR OM PCM

Figure 2F-80 (V6 and S/C V6)

Figure 2F-81 (GEN III V8)

Circuit Description:

When investigating any complaint of an OCC problem or malfunction, always begin diagnosis with the following

diagnostic circuit check. This check is a preliminary procedure that checks to ensure the OCC module is

communicating on the serial data line as well as helping to identify a problem or malfunction and directing the

reader to the appropriate diagnostic chart in this Section.

With TECH 2 connected to the DLC and ignition switched on, TECH 2 should display serial data communication.

If TECH 2 does not display serial d ata, the serial data circuit may be open or shorted.

There are several other control modules that are connected to the serial data line (PCM, BCM, ABS/TCS,

instruments and SDM. Any of these control modules could cause a fault on the serial data line. This fault could

result in TECH 2 not being able to display serial data.

DTC will set if the serial data line (circuits 1061 or 800) are interrupted and the OCC does not receive data from the

PCM or BCM fo r 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart

1. Ensures the Diagnostic Circuit Check has been performed.

2. Determines if there is a fault in the serial data circuit (800) between the BCM and PCM by starting the engine.

If serial data was lost while the engine was running, the engine will restart but there will b e a one second delay.

3. Checks if fault is common with other control modules connected to the serial data circuit.

4. Checks internal switch in BCM for open circuit.

5. Checks circuit 1061 and determine if fault is in wiring or a control module.

6. Checks circuit 1061 for open circuit.

7. Checks integrity of ground circuits for the BCM, PCM, PIM and OCC control module.

Diagnostic Aids:

A fault with the serial data circuit could be caused by one or more of the several control modules connected to this

serial data circuit. Isolate the fault by disconnecting each control module, one at a time until serial data

communication is re stored.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAG NOSTICS in this Section for connecting and using TECH 2.

3. To check the integrity of the OCC module ground circuit; turn ignition and OCC system ON and check for a

voltage drop across circuit 251 (Black / Yellow wire), between OCC module connector A14 X1, terminal X1-2,

and ground point X157.

4. To check the integrity of the PCM ground circuit, refer to Ground Credibility Check in the following Sections:

• Section 6C1, POWERTRAIN – V6

• Section 6C2, POWERTRAIN – V6 S/C

• Section 6C3, POWERTRAIN – GEN III V8

DTC 35 – NO SERIAL DAT A FR OM PCM DIAGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC.

2. Select Diagnostics / Model Year / Vehicle

Model / Body / DTC Check / DTC Check.

Can TECH 2 communicate with the BCM and

PCM?

NOTE: If No Data displays next to a module, then

there is no communication between TECH 2 and

that module.

– Go to Step 3. G o to Sectio n

12J, 4.2 SERIAL

DATA

COMMUNICATI

ON (BUS

MASTER).

3 In Step 2, did TECH 2 communicate with all control

modules except the OCC control module? – Go to Step 7. Go to Step 4.

4 1. Back-probe between BCM connector

terminal X2-9, circuit 1061 (Green / White

wire) and X2-5, circuit 800 (Red / Black wire)

with an ohmmeter. (Refer to Notes on

Diagnostic Chart for this chart, Note 1.)

Is the value as specified?

Less than

1 ohm Go to Step 5. Replace the

BCM. Refer to

Section 12J, 2.1

BODY

CONTROL

MODULE.

5 1. Check the integrity of circuit 1061 (Green /

White wire) between BCM connector

terminal X2-9 and the individual control

modules.

Is the circuit OK?

– Go to Step 6. Repair faulty

circuit 1061.

STEP ACTION VALUE YES NO

6 1. Disconnect each control module in

circuit 1061 one at a time to isolate the fault

in the circuit or to identify the control module

causing the fault.

– Verify repair. Go to Step 7.

7 1. Back-probe between BCM connector

terminal X2-9 and OCC module connector

terminal X1-6, circuit 1061 (Green/White

wire) with an ohmmeter.

Is the value as specified?

Less than

1 ohm. Go to Step 8. Repair faulty

circuit 1061.

8 1. Check the integrity of the ground circuits to

the OCC control module, BCM, PCM and

PIM (GEN III V8) using a voltmeter to a

known good ground. (Refer to Notes on

Diagnostic Chart for this chart, Notes 3

and 4.)

Are the values as specified?

Less than

0.15 volt. Replace the

OCC control

module. Refer

to Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATIO

Repair faulty

ground circuit/ s.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 36 – NO SERIAL DATA FROM BCM

Figure 2F-82 (V6 and S/C V6)

Figure 2F-83 (GEN III V8)

Circuit Description:

When investigating any complaint of an OCC problem or malfunction, always begin diagnosis with the following

diagnostic circuit check. This check is a preliminary procedure that checks to ensure the OCC module is

communicating on the serial data line as well as helping to identify a problem or malfunction and directing the

reader to the appropriate diagnostic chart in this section.

With TECH 2 connected to the DLC and ignition switched on, TECH 2 should display serial data communication.

If TECH 2 does not display serial d ata, the serial data circuit may be open or shorted.

There are several other control modules that are connected to the serial data line (PCM, BCM, ABS/TCS,

instruments and SDM. Any of these control modules could cause a fault on the serial data line. This fault could

result in TECH 2 not being able to display serial data.

DTC will set if set if the serial data line (circuits 1061 or 800) are interrupted and the OCC module does not receive

data from the PCM or BCM for 10 seconds.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart

1. Ensures the Diagnostic Circuit Che ck has been performed.

2. Determines if there is a fault in the serial data circuit (800) between the BCM and PCM by starting the engine.

If serial data was lost while the engine was running, the engine will restart but there will b e a one second delay.

3. Checks if fault is common with other control modules connected to the serial data circuit.

4. Checks internal switch in BCM for open circuit.

5. Checks circuit 1061 and determines if fault is in wiring or a control module.

6. Checks circuit 1061 for open circuit.

7. Checks integrity of ground circuits for the BCM, PCM, PIM and OCC control module.

Diagnostic Aids:

A fault with the serial data circuit could be caused by one or more of the several control modules connected to this

serial data circuit. Isolate the fault by disconnecting each control module, one at a time until serial data

communication is re stored.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

To check the integrity of the OCC module ground circuit; turn ignition and OCC system ON and check for a voltage

drop across circuit 251 (Black / Yellow wire), between OCC module connector A14 X1, terminal X1-2, and

ground point X157.

To check the integrity of the BCM ground circuit turn the ignition on and check for a voltage drop across circuit 251

(Black / Yellow wire), between BCM connector A15 X1, terminal X1-20 and ground point X157.

To check the integrity of the PCM ground circuit, refer to Ground Credibility Check in the following Sections:

• Section 6C1, POWERTRAIN – V6

• Section 6C2, POWERTRAIN – V6 S/C

• Section 6C3, POWERTRAIN – GEN III V8.

DTC 36 – SERIAL DATA COMMUNICATION ERROR DI AGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Connect TECH 2 to the DLC.

2. Select Diagnostics / Model Year / Vehicle

Model / Body / DTC Check / DTC Check.

Can TECH 2 communicate with the BCM and

PCM?

NOTE: If No Data displays next to a module, then

there is no communication between TECH 2 and

that module.

– Go to Step 3. G o to Sectio n

12J, 4.2 SERIAL

DATA

COMMUNICATI

ON (BUS

MASTER).

3 In Step 2, did TECH 2 communicate with all the

control modules, except the OCC module (ABS,

instruments, SRS)?

– Go to Step 7. Go to Step 4.

4 1. Check the integrity of circuit 1061 (Green /

White wire) and circuit 800 (Red / Black wire)

between BCM connector terminals X2-5 and

X2-9. (Refer to Notes on Diagnostic Chart for

this chart, Note 1.)

Are the circuits OK?

– Go to Step 5. Repair faulty

circuit 800

STEP ACTION VALUE YES NO

5 1. Check the integrity of circuit 1061 (Green /

White wire) between BCM and the individual

control modules.

– Go to Step 6. Repair faulty

circuit 1061.

6 1. Disconnect each control module in

circuit 1220 one at a time to isolate the fault

in the circuit or to identify the control module

causing the fault.

Was a fault located and rectified?

– Verify repair. Go to Step 7.

7 1. Back-probe between BCM connector

terminal X2-9 and OCC module connector

terminal X1-6, circuit 1061 (Green / White

wire) with an ohmmeter.

Is the value as specified?

Less than

1 ohm Go to Step 8. Repair faulty

circuit 1061.

8 1. Check the integrity of the ground circuits to

the OCC module, BCM, PCM and PIM

(GEN III V8) with a voltmeter to a known

good ground.

Is the value as specified?

Less than

0.15 volts Replace the

OCC control

module. Refer

to Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATIO

Repair faulty

ground circuit/ s.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 37 – ROM CHECKSUM ERROR

Figure 2F-84

Circuit Description:

When this diagnostic trouble code (DTC) is set, it indicates a failure attributed to the processor. The processor is

part of the printed circuit board (1) installed within the rear housing (2) of the OCC modul e (3).

DTC 37 will set: if the ROM checksum is incorrect. The testing of the ROM checksum occurs every time the OCC

system is reset due to battery disconnection or lo w power conditions.

If DTC 37 sets and reprogramming is unsuccessful, replace the OCC control module.

Refer to Section 2E, 2.1 OCC CONTROL MODULE.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart.

1. Ensures the Diagnostic Circuit Che ck has been performed.

2. Determines if OCC module is faulty by re-programming the OCC control module.

3. Determines if OCC module is faulty.

Notes on Diagnostic Chart:

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

Diagnostic Aids:

If the OCC system programming is corrupted, recalibration can be carried out via TECH 2. To calibrate the system

refer to 1.2 TECH 2 TEST MODES AND DISPLAYS FOR OCC DIAGNOSIS in this Section.

DTC 37 – ROM CHECKSUM ERROR

Step Action Yes No

1 1 Has the Diagnostic Circuit Check been performed? Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT CHECK

in this Section.

1. Reprogram the OCC module Code Version using TECH 2.

Refer to 1.2 TECH 2 TEST MODES AND SCREEN

DISPLAYS FOR OCC DIAGNOSIS in this Section.

Was programming successful?

Go to Step 4. Go to Step 3.

3 1. Repeat Step 2 at least twice, as the system may have

crashed during the prog ramming process.

Was programming successful?

Go to Step 4. Go to Step 5.

1. Connect TECH 2 to the DLC.

2 Select Diagnostics / Model Year / Vehicle Model / Body /

Occupant Control Module / Diagnostic Trouble Codes / Clear

DTC Information and clea r DTCs.

Were all DTCs cleared?

System OK. Go to Step 5.

1. Replace the OCC control module. Refer to Section 2E,

HVAC OCCUPANT CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Is the replacement completed?

Verify system –

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR ALL D TC AND VERIFY CORRECT

OPERATION

DTC 38 – EEPROM CHECKSUM ERROR

Figure 2F-85

Circuit Description:

The EEPROM (Expandable, Erasable Program, Read Only, Memory) is part of the printed circuit board (1) installed

within the rear housing (2) of the OCC module (3).

The function of the EEPROM is to store data used to control operating parameters of the OCC system.

When this DTC is set, and the EEPROM checksum is incorrect. The OCC system calibration is corrupted or the

EEPROM in the OCC module has failed.

DTC 38 will set when the EEPROM checksum is incorrect. The testing of the EEPROM occurs whenever the

ignition is turned on.

If DTC 38 sets and reprogramming is unsuccessful, replace the OCC control module.

Refer to Section 2E, 2.1 OCC CONTROL MODULE.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Che ck has been performed.

2. Determines if OCC module is faulty by re-programming the OCC control module.

3. Determines if OCC module is faulty.

Notes on Diagnostic Chart:

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

Diagnostic Aids:

If the OCC system programming is corrupted, recalibration can be carried out via TECH 2. To calibrate the system

refer to 1.2 TECH 2 TEST MODES AND DISPLAYS FOR OCC DIAGNOSIS in this Section.

DTC 38 – EEPROM CHECKSUM ERROR DIAGNOSTIC CHART

Step Action Yes No

1 1 Has the Diagnostic Circuit Check been performed? Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT CHECK

in this Section.

1. Reprogram the OCC module Code Version using TECH 2.

Refer to 1.2 TECH 2 TEST MODES AND SCREEN

DISPLAYS FOR OCC DIAGNOSIS in this Section.

Was programming successful?

Go to Step 4. Go to Step 3.

3 1. Repeat Step 2 at least twice, as the system may have

crashed during the prog ramming process.

Was programming successful?

Go to Step 4. Go to Step 5.

1. Connect TECH 2 to the DLC.

2 Select Diagnostics / Model Year / Vehicle Model / Body /

Occupant Control Module / Diagnostic Trouble Codes / Clear

DTC Information and clea r DTCs.

Were all DTCs cleared?

System OK. Go to Step 5.

1. Replace the OCC control module. Refer to Section 2E,

HVAC OCCUPANT CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Is the replacement completed?

Verify system –

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR ALL D TC AND VERIFY CORRECT

OPERATION

DTC 39 – RAM ERROR

Figure 2F-86

Circuit Description:

The RAM (Random Access Memory) is part of the printed circuit board (1) installed within the rear housing (2) of

the OCC module (3).

The function of the RAM is to store data used to control operating parameters of the OCC system.

When this DTC is set, it indicates that the RAM has been corrupted or failed.

DTC 39 will set when the microprocessor RAM test fails. The RAM is tested every time the cluster performs a cold

reset due to battery disconnection.

If DTC 39 sets and reprogramming is unsuccessful, replace the OCC control module.

Refer to Section 2E, 2.1 OCC CONTROL MODULE.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Che ck has been performed.

2. Determines if OCC module is faulty by re-programming the OCC control module.

3. Determines if OCC module is faulty.

Notes on Diagnostic Chart:

1. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2..

Diagnostic Aids:

If the OCC system programming is corrupted, recalibration can be carried out via TECH 2. To calibrate the system

refer to 1.2 TECH 2 TEST MODES AND DISPLAYS FOR OCC DIAGNOSIS in this Section.

DTC 39 – RAM ERROR DIAGNOSTIC CHART

Step Action Yes No

1 1 Has the Diagnostic Circuit Check been performed? Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT CHECK

in this Section.

1. Reprogram the OCC module Code Version using TECH 2.

Refer to 1.2 TECH 2 TEST MODES AND SCREEN

DISPLAYS FOR OCC DIAGNOSIS in this Section.

Was programming successful?

Go to Step 4. Go to Step 3.

3 1. Repeat Step 2 at least twice, as the system may have

crashed during the prog ramming process.

Was programming successful?

Go to Step 4. Go to Step 5.

1. Connect TECH 2 to the DLC.

2 Select Diagnostics / Model Year / Vehicle Model / Body /

Occupant Control Module / Diagnostic Trouble Codes / Clear

DTC Information and clea r DTCs.

Were all DTCs cleared?

System OK. Go to Step 5.

1. Replace the OCC control module. Refer to Section 2E,

HVAC OCCUPANT CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Is the replacement completed?

Verify system –

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR ALL D TC AND VERIFY CORRECT

OPERATION

DTC 40 – AIR MIX DOOR MOTOR DRIVER ERROR (LHD)

Figure 2F-87

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, and in turn moves the air mix door towards or

away from the heater core. The direction change takes place by reversing the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit which, feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

NOTE 1: Refer to Figure 2F-87 for LHD vehicles.

NOTE 2: Refer to Figure 2F-88 a nd Figure 2F-89 for RHD drive vehicles.

DTC 40 will set when the Air Mix Motor Driver detects an error condition for a period of 1 second. An error condition

occurs when the Air Mix Motor Outputs are dra wing e xcessive current or operating with an excessive voltage.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks to see whether the OCC is faulty.

This test checks whether the resistance across terminals X2-1 and X2-2 indicat es a faulty connector or open circuit.

This test checks whether the resistance across terminals X2-1 and X2-2 indicates a faulty circuit or air mix door

motor.

This test checks for a short to ground in circuit 1199.

This test checks for a short in circuit 1199 or 61.

This test checks for a short in circuit 1199 or 27 4.

This test checks for a short in circuit 1199 or 73 3.

This test checks for intermittent or loose terminals.

This test checks for open in circuits 1199 or 733.

This test checks for faulty connectors.

Ensures that DTC 43 has been cleared if present.

Ensures that DTC 44 has been cleared if present.

This test checks for physical fault in drivers air mix door motor.

This test determines if the drivers air mix door motor is faulty.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 40 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 40 will be set again.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 40 – AIR MIX DOOR MOTOR DRIVER ERROR (LHD) DIAGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness

connector A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data

Display / Data List / Drivers Air Mix Door

Feedback.

Does TECH 2 display a value more than 4.8 volts?

– Go to Step 3. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-1, circuit 1199 (Red

wire) and connector terminal X2-2, circuit 733

(Black wire) with an ohmmeter.

Is the value as specified?

Less than

80 ohms Go to Step 4. Go to Step 9.

4 In Step 3, was the value specified? Less than

70 ohms Go to Step 8. Go to Step 5.

5 1. With the OCC connector A14 X2

disconnected, probe terminal X2-1,

circuit 1199 (Red wire) with an ohmmeter to

chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuit 1199. Go to Step 6.

6 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-1, circuit 1199 (Red

wire) and connector terminal X2-15, circuit 61

(White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuit 1199

and/or 61.

Go to Step 7.

STEP ACTION VALUE YES NO

7 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-1, circuit 199 (Red

wire) and connector terminal X2-5, circuit 274

(Red / White wire) with an ohmmete r.

– Repair faulty

circuits 1199

and/or 274.

Go to Step 11.

8 1. Disconnect the driver’s air mix door motor

connector Y37 LHD X1.

With the OCC connector A14 X2 disconnected,

probe between OCC connector terminal X2-1,

circuit 1199 (Red wire) and connector

terminal X2-2, circuit 733 (Black wire) with an

ohmmeter.

Does the meter indicate a short?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuit1199

and/or 733.

Replace the

drivers air mix

door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

9 1. Inspect wiring harness connectors A14 X2

and Y37 LHD X1 for an intermittent or loose

terminal.

Are the connectors OK?

– Go to Step 10. Repair faulty

connector/s.

10 1. Check the integrity of circuit 1199 and

circuit 733.

Are the circuits OK?

– Replace air mix

door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit 1199

and/or 733.

11 1. Inspect wiring harness connectors A14 X2

and Y37 LHD X1 for an intermittent or loose

terminal and for a short circuit between

terminals.

Are the connectors OK?

– Go to Step 12. Repair faulty

connector/ s.

12 Does DTC 43 set as a curr ent DTC? – Go to Chart

DTC 43 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

(LHD) in this

Section.

Go to Step 13.

STEP ACTION VALUE YES NO

13 Does DTC 44 set as a curr ent DTC? – Go to Chart

DTC 44 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH (LHD) in

this Section.

Go to Step 14.

14 1. Remove the driver’s air mix motor assembly.

Refer to Section 2E, HVAC OCCUPANT

CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 15.

15 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem resolved?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 40 – AIR MIX DOOR MOTOR DRIVER ERROR (RHD DRIVERS SIDE MOTOR)

Figure 2F-88

Circuit Description:

DTC 40 will set when the Air Mix Motor Driver detects an error condition for a period of 1 second. An error condition

occurs when the Air Mix Motor Outputs are dra wing e xcessive current or operating with an excessive voltage.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks to see whether the OCC is faulty.

This test checks whether the resistance across terminals X2-1 and X2-2 indicat es a faulty connector or open circuit.

This test checks whether the resistance across terminals X2-1 and X2-2 indicates a faulty circuit or air mix door

motor.

This test checks for a short to ground in circuit 1199.

This test checks for a short in circuit 1199 or 61.

This test checks for a short in circuit 1199 or 27 4.

This test checks for a short in circuit 1199 or 73 3.

This test checks for intermittent or loose terminals.

This test checks for open in circuits 1199 or 733.

This test checks for faulty connectors.

Ensures that DTC 43 has been cleared if present.

Ensures that DTC 44 has been cleared if present.

This test checks for physical fault in drivers air mix door motor.

This test determines if the drivers air mix door motor is faulty.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 40 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 40 will be set again.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 40 – AIR MIX DOOR MOTOR DRIVER ERROR (RHD DRIVERS SIDE MOTOR) DIAGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness

connector A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data

Display / Data List / Drivers Air Mix Door

Feedback.

Does TECH 2 display a value more than4.8 volts?

– Go to Step 3. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-1, circuit 1199 (Red

wire) and connector terminal X2-2, circuit 733

(Black wire) with an ohmmeter.

Is the value as specified?

Less than

80 ohms Go to Step 4. Go to Step 9.

4 In Step 3, was the value as specified? Less than

70 ohms Go to Step 8. Go to Step 5.

5 1. With the OCC connector A14 X2

disconnected, probe terminal X2-1,

circuit 1199 (Red wire) with an ohmmeter to

chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuit 1199. Go to Step 6.

6 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-1, circuit 1199 (Red

wire) and connector terminal X2-15, circuit 61

(Tan wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuit 1199

and/or 61.

Go to Step 7.

7 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-1, circuit 199 (Red

wire) and connector terminal X2-5, circuit 274

(Red / White wire) with an ohmmete r.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuits 1199

and/or 274.

Go to Step 11.

8 1. Disconnect the driver’s air mix door motor

connector Y37 R X1.

With the OCC connector A14 X2 disconnected,

probe between OCC connector terminal X2-1,

circuit 1199 (Red wire) and connector

terminal X2-2, circuit 733 (Black wire) with an

ohmmeter.

Does the meter indicate a short?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuit1199

and/or 733.

Replace the

drivers air mix

door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

STEP ACTION VALUE YES NO

9 1. Inspect wiring harness connectors A14 X2

and Y37 R X1 for an intermittent or loose

terminal.

– Go to Step 10. Repair faulty

connector/s.

10 1. Check the integrity of circuit 1199 and

circuit 733.

Are the circuits OK?

– Replace air mix

door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit 1199

and/or 733.

11 1. Inspect wiring harness connectors A14 X2

and Y37 R X1 for an intermittent or loose

terminal and for a short circuit between

terminals.

Are the connectors OK?

– Go to Step 12. Repair faulty

connector/ s.

12 Does DTC 43 set as a curr ent DTC? – Go to Chart

DTC 43 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

(LHD) in this

Section.

Go to Step 13.

13 Does DTC 44 set as a curr ent DTC? – Go to Chart

DTC 44 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH (LHD) in

this Section.

Go to Step 14.

14 1. Remove the driver’s air mix motor assembly.

Refer to Section 2E, HVAC OCCUPANT

CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 15.

15 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem fixed?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 40 – AIR MIX DOOR MOTOR DRIVER ERROR (RHD PASSENGERS SIDE MOTOR)

Figure 2F-89

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, and in turn moves the air mix door towards or

away from the heater core. The direction change takes place by reversing the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit which, feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 40 will set when the Air Mix Motor Driver detects an error condition for a period of 1 second. An error condition

occurs when the Air Mix Motor Outputs are dra wing e xcessive current or operating with an excessive voltage.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks to see whether the OCC is faulty.

This test checks whether the resistance across terminals X2-3 and X2-4 indicat es a faulty connector or open circuit.

This test checks whether the resistance across terminals X2-3 and X2-4 indicates a faulty circuit or air mix door

motor.

This test checks for a short to ground in circuit 1236.

This test checks for a short in circuit 1236 or 61.

This test checks for a short in circuit 1236 or 27 4.

This test checks for a short in circuit 1236 or 1646.

This test checks for intermittent or loose terminals.

This test checks for open in circuits 1236 or 1646.

This test checks for faulty connectors.

Ensures that DTC 45 has been cleared if present.

Ensures that DTC 46 has been cleared if present.

This test checks for physical fault in drivers air mix door motor.

This test determines if the drivers air mix door motor is faulty.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 40 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 40 will be set again.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 40 – AIR MIX DOOR MOTOR DRIVER ERROR (RHD PASS ENGERS SIDE MOTOR)

STEP ACTION VALUE YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness

connector A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data

Display / Data List / Drivers Air Mix Door

Feedback.

Does TECH 2 display a value above 4.8 volts?

– Go to Step 3. Replace the

OCC control

module, refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-3, circuit 1236 (Brown

wire) and connector terminal X2-4,

circuit 1646 (Light-Blue wire) with an

ohmmeter.

Is the value as specified?

Less than

80 ohms Go to Step 4. Go to Step 9.

4 In Step 3, was the value as specified? Less than

70 ohms Go to Step 8. Go to Step 5.

5 1. With the OCC connector A14 X2

disconnected, probe connector terminal X2-3,

circuit 1236 (Brown wire) with an ohmmeter

to chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuit 1236. Go to Step 6.

STEP ACTION VALUE YES NO

6 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-3, circuit 1236 (Brown

wire) and connector terminal X2-15, circuit 61

(Tan wire) with an ohmmeter.

– Repair faulty

circuit 1236

and/or 61.

Go to Step 7.

7 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-3, circuit 1236 (Brown

wire) and connector terminal X2-5, circuit 274

(Red / White wire) with an ohmmete r.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuit 1236

and/or 274.

Go to Step 11.

8 1. Disconnect air mix door motor connector

Y37 L X1.

With the OCC connector A14 X2 disconnected,

probe between terminals X2-3, circuit 1236

(Brown wire) and X2-4, circuit 1646 (Light-Blue

wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

– Repair faulty

circuits 1236

and/or 1646.

Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

9 1. Inspect wiring harness connectors A14 X2

and Y37 L X1 for an intermittent or loose

terminal.

Are the connectors OK?

– Go to Step 10. Repair faulty

connector/s.

10 1. Check the integrity of circuits 1236 and 1646.

Are the circuits OK? – Repair faulty

circuit 1236

and/or 1646.

Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

11 1. Inspect the wiring harness connectors

A14 X2 and Y37 L X1 for an intermittent or

loose terminal and for a short circuit between

terminals.

Are the connectors OK?

– Go to Step 12. Repair faulty

connector/ s.

STEP ACTION VALUE YES NO

12 Does DTC 45 set as a curr ent DTC? – Go to Chart

DTC 45 –

PASSENGERS

AIR MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

in this Section.

Go to Step 13.

13 Does DTC 46 set as a curr ent DTC? – Go to Chart

DTC 46 –

PASSENGERS

AIR MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH in this

Section.

Go to Step 14.

14 1. Remove the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 15.

15 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem fixed?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 41 – SOLENOID DRI VER ERROR – LHD

Figure 2F-90

Circuit Description:

The solenoid pack is activated when the OCC system is turned on. Individual solenoids are grounded by via the

OCC control module. In accordance to switching signals generated manually or automatically at the OCC control

module, the solenoid pack directs vacuum to the various vacuum actuators to achieve the desired ventilation mode.

It also activates the water valve for heating and demisting purposes.

DTC 41 will set when the Solenoid Driver detects an error condition for a period of 1 second. An error condition

occurs when the Solenoid Outputs are drawing excessive current and / or have reached an over temperature

condition.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks the power supply to the solenoid pack.

This test checks for open in circuit 274 between the solenoid pack and the OCC control modu le.

This test checks power supply to heater water shut off valve.

This test checks for open in circuit 274 between heater water shut off valve and OCC control module.

This test checks the functioning of the Face 1 sole noid.

This test checks the functioning of the Face 2 sole noid.

This test checks the functioning of the Feet solenoid.

This test checks the functioning of the DFG solen oid.

This test checks the functioning of the Fresh / Recirc solenoid.

This test checks the functioning of the WAT solenoid.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

DTC 41 – SOLENOID DRIVER ERROR – LHD DIAGNOSTIC CHART

STEP ACTION VALUE YES

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Turn the ignition on.

2. Back-probe connector Y19 LHD terminal X1-1,

circuit 274 (Red / White wire) with a voltmeter to

ground.

Is the value as specified?

4.5 volts Go to Step 3. Repair faulty

circuit 274.

3 1. Turn the ignition off.

Back-probe between OCC module connector

terminal X2-5, circuit 274 (Red / White wire) and

the solenoid pack connector Y19 LHD

terminal X1-1 circuit 274 (Red / White wire) with

an ohmmeter.

Is the value as specified?

Less than

1 ohm Go to Step 4. Repair faulty

circuit 274.

4 1. Turn the ignition on.

Back-probe connector Y18 LHD terminal X1-1,

circuit 274 (Red / White wire) with a voltmeter to

ground.

Is the value as specified?

12 volts Go to Step 5. Repair faulty

circuit 274.

5 1. Turn the ignition off.

Back-probe between OCC module connector

terminal X2-5 and solenoid pack connector

Y18 LHD terminal X1-1, circuit 274 (Red / White

wire) with an ohmmeter.

Is the value as specified?

– Go to Step 6. Repair faulty

circuit 274.

6 1. Turn the ignition on

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control /

Miscellaneous Tests / Solenoids.

Activate the Face 1 solenoid.

Does the Face 1 solenoid Activate?

– Go to Step 7. Go to OCC

Solenoid Pack

(LHD) test in

this Section.

STEP ACTION VALUE YES

7 1. With TECH 2 connected, activate the Face 2

solenoid. – Go to Step 8. Go to OCC

Solenoid Pack

(LHD) test in

this Section.

8 1. With TECH 2 connected, activate the Feet

solenoid.

Does the Feet solenoid activate?

– Go to Step 9. Go to OCC

Solenoid Pack

(LHD) test in

this Section.

9 1. With TECH 2 connected, activate the DFG

solenoid.

Does the DFG solenoid activate?

– Go to Step 10. Go to OCC

Solenoid Pack

(LHD) test in

this Section.

10 1. With TECH 2 connected, activate the

FRESH_RECIRC.

Does the FRESH_RECIRC solenoid activate?

– Go to Step 11. Go to OCC

Solenoid Pack

(LHD) test in

this Section.

11 1. With TECH 2 connected, activate the WAT

solenoid.

Does the WAT solenoid activate?

– System OK. Go to Water

Vacuum, Valve

Switch (LHD)

test in this

Section.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 41 – SOLENOID DRI VER ERROR – RHD

Figure 2F-91

Circuit Description:

The solenoid pack is activated when the OCC system is turned on. Individual solenoids are grounded by via the

OCC control module. In accordance to switching signals generated manually or automatically at the OCC control

module, the solenoid pack directs vacuum to the various vacuum actuators to achieve the desired ventilation mode.

It also activates the water valve for heating and demisting purposes.

DTC 41 will set when the Solenoid Driver detects an error condition for a period of 1 second. An error condition

occurs when the Solenoid Outputs are drawing excessive current and / or has reached an over temperature

condition.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks the power supply to the solenoid pack.

This test checks for open in circuit 274 between the solenoid pack and the OCC control modu le.

This test checks the functioning of the Fresh / Recirc solenoid.

This test checks the functioning of the Face 1 sole noid.

This test checks the functioning of the Face 2 sole noid.

This test checks the functioning of the Foot 1 solenoi d.

This test checks the functioning of the Foot 2 solenoi d.

This test checks the functioning of the Water sole noid

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

DTC 41 – SOLENOID DRIVER ERROR – RHD DIAGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Turn the ignition on.

Back-probe connector Y19 L terminal X1-4,

circuit 274(Red / White wire).

Is the value as specified?

4.5 volts Go to Step 3. Repair faulty

circuit 274.

3 1. Turn the ignition off.

Back-probe between the OCC module connector

terminal X2-5 and the solenoid pack connector

Y19 L terminal X1-4 circuit 274 (Red / White

wire).

Is the value as specified?

– Go to Step 4. Repair faulty

circuit 274.

4 1. Turn the ignition on

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control /

Miscellaneous Tests / Solenoids.

Activate the Fresh / Recirc solenoid.

Does the Fresh / Recirc solenoid Activate?

– Go to Step 5. Go to OCC

Solenoid Pack

(RHD) test in

this Section.

5 1. With TECH 2 connected, activate the Face 1

solenoid.

Does the Face 1 solenoid activate?

– Go to Step 6. Go to OCC

Solenoid Pack

(RHD) test in

this Section.

6 1. With TECH 2 connected, activate the Face 2

solenoid.

Does the Face 2 solenoid activate?

– Go to Step 7. Go to OCC

Solenoid Pack

(RHD) test in

this Section.

7 1. With TECH 2 connected, activate the Foot 1

solenoid.

Does the Foot 1 solenoid activate?

– Go to Step 8. Go to OCC

Solenoid Pack

(RHD) test in

this Section.

8 1. With TECH 2 connected, activate the Foot 2

solenoid.

Does the Foot 2 solenoid activate?

– Go to Step 9. Go to OCC

Solenoid Pack

(RHD) test in

this Section.

9 1. With TECH 2 connected, activate the Water

solenoid.

Does the Water solenoid activate?

– System OK. Go to OCC

Solenoid Pack

(RHD) test in

this Section.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 43 – DRIVER’S AIR MIX DOOR MOTOR FEEDBACK CIRCUIT VOLTAGE TOO LOW (LHD)

Figure 2F-92

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, and in turn moves the air mix door towards or

away from the heater core. The direction change takes place by reversing the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit which, feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 43 will set when the feedback si gnal from the Driver’s Air Mix Motor is open circuit for a period of 10 secon ds.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks for faulty OCC.

This test checks for short to ground in circuit 705.

This test checks for a short in circuits 705 and 1199.

This test checks for a short in circuits 705 and 274.

This test checks that the resistance value of the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the resistance value of the potentiometer is not less than the minimum acceptable tolerance.

This test checks that the signal from the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the signal from the potentiometer is not less than minimum acceptable to lerance.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for sufficient power supply for the potentiometer from the OCC.

This test checks for short in circuits 705 or 61.

This test checks for short in circuits 61 or 1791.

This test checks for short in circuits 705 or 1791.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for open in circuits 61, 1791 and 705.

Ensures that DTC 40 has been cleared if present.

This test checks to see if the air mix door is physically jammed or bro ken.

This test determines whether the air mix motor a ssem bly is faulty.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 43 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 43 will be set again.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 43 – DRIVERS AIR MIX DOOR MOTOR FEEDBACK CIRCUIT VOLTAGE TOO LOW (LHD)

STEP ACTION VALUE YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness connector

A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data Display

/ Data List / Drivers Air Mix Door Feedback.

Does TECH 2 display a value more than 4.8 volts?

– Go to Step 3. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. Install the driver’s air mix motor (if

disconnected).

With the OCC connector A14 X2 disconnected,

probe OCC connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter to

chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705. Go to Step 4.

4 1. With the OCC A14 X2 disconnected, probe

between OCC connector terminal X2-1,

circuit 1199 (Red wire) and connector

terminal X2-11, circuit 705 (White wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705

and/or 1199.

Go to Step 5.

STEP ACTION VALUE YES NO

5 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-5, circuit 274 (Red / White wire)

and connector terminal X2-11, circuit 705

(White wire) with an ohmmeter.

0 Ohm Repair faulty

circuit 274

and/or 705.

Go to Step 6.

6 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-11, circuit 705 (White wire) and

connector terminal X2-15, circuit 61 (White

wire) with an ohmmeter.

Is the value as specified?

Less than

12 kilohm Go to Step 7. Go to Step 15.

7 In Step 6, was the value as specified? More than

8 kilohms Go to Step 8. Go to Step 12.

8 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-11, circuit 705 (White wire) and

connector terminal X2-18, circuit 1791 (Green /

White wire) with an ohmmeter.

Is the value as specified?

Less than

8.5 kilohms Go to Step 9. Go to Step 15.

9 In Step 8, was the value as specified? More than

1.5 kilohms Go to Step 10. Go to Step 12.

10 1. Inspect the OCC wiring harness connector

A14 X2 and air mix motor connector Y37 L X1

for an intermittent or loose terminal.

Are the connectors OK?

– Repair faulty

connector/s. Go to Step11.

11 1. Install the OCC connectors A14 X2 and

A14 X1 to OCC module.

Disconnect the driver’s air mix motor connector

Y37 LHD X1.

Turn the ignition on.

Back-probe between the driver’s air mix motor

connector Y37 LHD X1 terminal X1-3, circuit 61

(White wire) and terminal X1-2 circuit 705 (White

wire).

Is the value as specified?

4.8 – 5.0

volts Go to Step 17. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C)–

REMOVAL &

INSTALLATION

12 1. Disconnect the air mix motor connector

Y37 LHD.

With the OCC connector A14 X2 disconnected,

probe between OCC connector terminal X2-11,

circuit 705 (White wire) and connector

terminal X2-15, circuit 61 (White wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

– Repair faulty

circuit 705

and/or 61.

Go to Step 13.

13 1. With OCC connectors A14 X2 and

Y37 LHD X1 disconnected, probe between

OCC connector terminal X2-15, circuit 61

(White wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

– Repair faulty

circuit 61 and/or

1791.

Go to Step 14.

STEP ACTION VALUE YES NO

14 1. With OCC connectors A14 X2 and

Y37 LHD X1 disconnected, probe between

OCC connector terminal X2-11, circuit 705

(White wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

– Repair faulty

circuit 705

and/or 1791.

Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

15 1. Inspect the wiring harness connectors A14 X2

and Y37 LHD X1 for an intermittent or loose

terminal.

Are the connectors OK?

– Go to Step 16. Repair faulty

connector/s.

16 1. Check the integrity of circuits 61, 1791 and

705.

Are the circuits OK?

– Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit/s.

17 Is DTC 40 currently recorded in TECH 2? – Go to DTC 40 in

this Section and

clear DTC.

Go to Step 18.

18 1. Remove the driver’s air mix motor assembly.

Refer to Section 2E, HVAC OCCUPANT

CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 19.

19 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem fixed?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 43 – DRIVERS AIR MIX DOOR MOTOR FEED B AC K CIRCUIT VOLTAGE TOO LOW ( R HD)

Figure 2F-93

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, and in turn moves the air mix door towards or

away from the heater core. The direction change takes place by reversing the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit which, feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 43 will set when the feedback si gnal from the Driver’s air mix motor is open circuit for a period of 10 seconds.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks for faulty OCC.

This test checks for short to ground in circuit 705.

This test checks for a short in circuits 705 and 1199.

This test checks for a short in circuits 705 and 274.

This test checks that the resistance value of the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the resistance value of the potentiometer is not less than the minimum acceptable tolerance.

This test checks that the signal from the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the signal from the potentiometer is not less than minimum acceptable to lerance.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for sufficient power supply for the potentiometer from the OCC.

This test checks for short in circuits 705 or 61.

This test checks for short in circuits 61 or 1791.

This test checks for short in circuits 705 or 1791.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for open in circuits 61, 1791 and 705.

Ensures that DTC 40 has been cleared if present.

This test checks to see if the air mix door is physically jammed or bro ken.

This test determines whether the air mix motor a ssem bly is faulty.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 43 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 43 will be set again.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 43 – DRIVERS AIR MIX DOOR MOTOR FEEDBACK CIRCUIT VOLTAGE TOO LOW (RHD) DI AGNOSTIC

CHART

STEP ACTION VALUE YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness

connector A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data

Display / Data List / Drivers Air Mix Door

Feedback.

Does TECH 2 display a value above 3.4 volts?

– Go to Step 3. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. Install the driver’s air mix motor (if

disconnected).

With the OCC connector A14 X2 disconnected,

probe OCC connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter to

chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohms Repair faulty

circuit 705. Go to Step 4.

4 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-1, circuit 1199 (Red

wire) and connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 705

and/or 1199.

Go to Step 5.

5 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-5, circuit 274 (Red /

White wire) and connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 274

and/or 705.

Go to Step 6.

STEP ACTION VALUE YES NO

6 1. Disconnect the passenger’s air mix motor

connector Y37 L X1 (if fitted). Less than

12 kilohms

Go to Step 7. Go to Step 15.

7 In Step 6, was the value as specified? More than

8 kilohms Go to Step 8. Go to Step 12.

8 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-11, circuit 705 (White

wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

Is the value as specified?

Less than

8.5 kilohms Go to Step 9. Go to Step 15.

9 In Step 8, was the value as specified? More than

1.5 kilohms Go to Step 10. Go to Step 12.

10 1. Inspect the OCC wiring harness connector

A14 X2 and the air mix motor connector

Y37 L X1 for an intermittent or loose terminal.

Are the connectors OK?

– Go to Step11. Repair faulty

connector/s.

11 1. Install OCC connectors A14 X2 and A14 X1.

Disconnect the driver’s air mix motor

connector Y37 R X1.

Turn the ignition on.

Back-probe between the driver’s air mix motor

connector Y37 R X1 terminal X1-1, circuit 61

(Tan wire) and terminal X1-3, circuit 705

(White wire).

Is the value as specified?

4.8 – 5.0

volts Go to Step 17. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C)–

REMOVAL &

INSTALLATION

12 1. Disconnect the air mix motor connectors

Y37 R X1 and Y37 L X1 (if fitted).

With the OCC connector A14 X2 disconnected,

probe between OCC connector terminal X2-11,

circuit 705 (White wire) and connector

terminal X2-15, circuit 61 (Tan wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 705

and/or 61.

Go to Step 13.

13 1. With OCC connectors A14 X2 and Y37 R X1

disconnected, probe between OCC

connector terminal X2-15, circuit 61 (Tan

wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 61 and/or

1791.

Go to Step 14.

STEP ACTION VALUE YES NO

14 1. With OCC connectors A14 X2 and Y37 R X1

disconnected, probe between OCC

connector terminal X2-11, circuit 705 (White

wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

0 Ohm Repair faulty

circuit 705

and/or 1791.

Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

15 1. Inspect the wiring harness connectors

A14 X2 and Y37 R X1 for an intermittent or

loose terminal.

Are the connectors OK?

– Go to Step 16. Repair faulty

connector/s.

16 1. Check the integrity of circuits 61, 1791 and

705.

Are the circuits OK?

– Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuit/s.

17 Is DTC 40 currently recorded in TECH 2? – Go to DTC 40 in

this Section and

clear DTC.

Go to Step 18.

18 1. Remove the driver’s air mix motor assembly.

Refer to Section 2E, HVAC OCCUPANT

CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 19.

19 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem fixed?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 44 – DRIVERS AIR MIX DOOR MOTOR FEEDBACK CIRCUIT VOLTAGE TOO HIG H ( LHD)

Figure 2F-94

Circuit Description:

The air mix motor is actually an electric motor used to operate the air mix door. The electric motor is sent a voltage

signal of 12.5 volts from the OCC module which causes the motor to turn, which moves the air mix door towards or

away from the heater core, the direction change takes place by reversing the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 44 will set when the feedback si gnal from the driver's air mix motor is short circuit for a period of 10 seconds.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks for faulty OCC.

This test checks for short to ground in circuit 705.

This test checks for a short in circuits 705 and 1199.

This test checks for a short in circuits 705 and 274.

This test checks that the resistance value of the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the resistance value of the potentiometer is not less than the minimum acceptable tolerance.

This test checks that the signal from the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the signal from the potentiometer is not less than minimum acceptable to lerance.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for sufficient power supply for the potentiometer from the OCC.

This test checks for short in circuits 705 or 61.

This test checks for short in circuits 61 or 1791.

This test checks for short in circuits 705 or 1791.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for open in circuits 61, 1791 and 705.

Ensures that DTC 40 has been cleared if present.

This test checks to see if the air mix door is physically jammed or bro ken.

This test determines whether the air mix motor assembly is faulty

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 44 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 44 will be set again.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 44 – DRIVERS AIR MIX DOOR MOTOR FEED BACK CIRCUIT VOLTAGE TOO HIGH (LHD) DIAGNOSTIC

CHART

STEP ACTION VALUE

YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness connector

A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data Display

/ Data List / Drivers Air Mix Door Feedback.

Does TECH 2 a value more than 4.8 volts?

– Go to Step 3. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. Install the driver’s air mix motor (if

disconnected).

With the OCC connector A14 X2 disconnected,

probe OCC connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter to

chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705. Go to Step 4.

4 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-1, circuit 1199 (Red wire) and

connector terminal X2-11, circuit 705 (White

wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705

and/or 1199.

Go to Step 5.

5 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-5, circuit 274 (Red / White wire)

and connector terminal X2-11, circuit 705

(White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 274

and/or 705.

Go to Step 6.

STEP ACTION VALUE

YES NO

6 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-11, circuit 705 (White wire) and

connector terminal X2-15, circuit 61 (White

wire) with an ohmmeter.

Less than

12 kilohms Go to Step 7. Go to Step 15.

7 In Step 6, was the value as specified? More than

8 kilohms Go to Step 8. Go to Step 12.

8 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-11, circuit 705 (White wire) and

connector terminal X2-18, circuit 1791 (Green /

White wire) with an ohmmeter.

Is the value as specified?

Less than

8.5 kilohms Go to Step 9. Go to Step 15.

9 In Step 8, was the value as specified? More than

1.5 kilohms Go to Step 10. Go to Step 12.

10 1. Inspect the OCC wiring harness connector

A14 X2 for an intermittent or loose terminal.

Are the connectors OK?

– Repair faulty

connector/s. Go to Step11.

11 1. Install the OCC connectors A14 X2 and

A14 X1.

Disconnect the driver’s air mix motor connector

Y37 LHD X1.

Turn the ignition on

Probe the driver’s air mix motor connector

Y37 LHD X1 between OCC connector

terminal X1-3 circuit 61 (White wire) and

terminal X1-2 circuit 705 (White wire) with a

voltmeter.

Is the value as specified?

4.8 – 5.0

volts Go to Step 17. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C)–

REMOVAL &

INSTALLATION

12 1. Disconnect the air mix motor connector

Y37 LHD X1.

With the OCC connector A14 X2 disconnected,

probe between OCC connector terminal X2-11,

circuit 705 (White wire) and connector

terminal X2-15, circuit 61 (White wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705

and/or 61.

Go to Step 13.

13 1. With OCC connectors A14 X2 and

Y37 LHD X1 disconnected, probe between

OCC connector terminal X2-15, circuit 61

(White wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 61 and/or

1791.

Go to Step 14.

14 1. With OCC connectors A14 X2 and

Y37 LHD X1 disconnected, probe between

OCC connector terminal X2-11, circuit 705

(White wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705

and/or 1791.

Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

STEP ACTION VALUE

YES NO

15 1. Inspect wiring harness connectors A14 X2 and

Y37 LHD X1 for an intermittent or loose

terminal.

– Go to Step 16. Repair faulty

connector/s.

16 1. Check the integrity of circuits 61, 1791 and

705.

Are the circuits OK?

– Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuits.

17 Is DTC 40 currently recorded in TECH 2? – Go to DTC 40 in

this Section and

clear DTC.

Go to Step 18.

18 1. Remove the driver’s air mix motor assembly.

Refer to Section 2E, HVAC OCCUPANT

CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 19.

19 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem fixed?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 44 – DRIVERS AIR MIX DOOR MOTOR FEEDBACK CIRCUIT VOLTAGE TOO HIG H (RH D)

Figure 2F-95

Circuit Description:

The air mix motor is actually an electric motor used to operate the air mix door. The electric motor is sent a voltage

signal of 12.5 volts from the OCC module which causes the motor to turn, which moves the air mix door towards or

away from the heater core, the direction change takes place by reversing the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 44 will set when the feedback signal from the driver’s air mix motor is short circuited for a period of 10

seconds.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks for faulty OCC.

This test checks for short to ground in circuit 705.

This test checks for a short in circuits 705 and 1199.

This test checks for a short in circuits 705 and 274.

This test checks that the resistance value of the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the resistance value of the potentiometer is not less than the minimum acceptable tolerance.

This test checks that the signal from the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the signal from the potentiometer is not less than minimum acceptable to lerance.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for sufficient power supply for the potentiometer from the OCC.

This test checks for short in circuits 705 or 61.

This test checks for short in circuits 61 or 1791.

This test checks for short in circuits 705 or 1791.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for open in circuits 61, 1791 and 705.

Ensures that DTC 40 has been cleared if present.

This test checks to see if the air mix door is physically jammed or bro ken.

This test determines whether the air mix motor a ssem bly is faulty.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 44 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 44 will be set again.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 44 – DRIVERS AIR MIX DOOR MOTOR FEED B AC K CIRCUIT VOLTAGE TOO HIGH (RH D) DIAGNOSTIC

CHART

STEP ACTION VALUE YES NO

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness

connector A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data

Display / Data List / Drivers Air Mix Door

Feedback.

Does TECH 2 display a value above 3.4 volts?

– Go to Step 3. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. Install the driver’s air mix motor (if

disconnected).

With the OCC connector A14 X2 disconnected,

probe OCC connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter to

chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 705. Go to Step 4.

4 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-1, circuit 1199 (Red

wire) and connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 705

and/or 1199.

Go to Step 5.

5 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-5, circuit 274 (Red /

White wire) and connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 274

and/or 705.

Go to Step 6.

STEP ACTION VALUE YES NO

6 1. Disconnect the passengers air mix motor

connector Y37 L X1 (if fitted). Less than

12 kilohms

Go to Step 7. Go to Step 15.

7 In Step 6, was the value as specified? More than

8 kilohms Go to Step 8. Go to Step 12.

8 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-11, circuit 705 (White

wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

Is the value as specified?

Less than

8.5 kilohms Go to Step 9. Go to Step 15.

9 In Step 8, was the value as specified? More than

1.5 kilohms Go to Step 10. Go to Step 12.

10 1. Inspect the OCC wiring harness connector

A14 X2 or air mix motor connector Y37 L X1

for an intermittent or loose terminal.

Are the connectors OK?

– Repair faulty

connector/s. Go to Step11.

11 1. Install the OCC connectors A14 X2 and

A14 X1.

Disconnect the driver’s air mix motor

connector Y37 R X1.

Turn the ignition on.

Probe the driver’s air mix motor connector

Y37 R X1 between terminals X1-1 circuit 61

(Tan wire) and X1-3 circuit 705 (White wire)

with a voltmeter.

Is the value as specified?

4.8 – 5.0

volts Go to Step 17. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C)–

REMOVAL &

INSTALLATION

12 1. Disconnect the air mix motor connectors

Y37 R X1 and Y37 L X1 (if fitted).

With the OCC connector A14 X2 disconnected,

probe between OCC connector terminal X2-11,

circuit 705 (White wire) and connector

terminal X2-15, circuit 61 (Tan wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 705

and/or 61.

Go to Step 13.

13 1. With OCC connectors A14 X2 and Y37 R X1

disconnected, probe between OCC

connector terminal X2-15, circuit 61 (Tan

wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair short in

circuit 61 and/or

1791.

Go to Step 14.

STEP ACTION VALUE YES NO

14 1. With OCC connectors A14 X2 and Y37 R X1

disconnected, probe between OCC

connector terminal X2-11, circuit 705 (White

wire) and connector terminal X2-18,

circuit 1791 (Green / White wire) with an

ohmmeter.

0 Ohm Repair faulty

circuit 705

and/or 1791.

Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

15 1. Inspect wiring harness connectors A14 X2

and Y37 R X1 for an intermittent or loose

terminal.

Are the connectors OK?

– Go to Step 16. Repair faulty

connector/s.

16 1. Check the integrity of circuits 61, 1791 and

705.

Are the circuits OK?

– Repair faulty

circuits. Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

17 Is DTC 40 currently recorded in TECH 2? – Go to DTC 40 in

this Section and

clear DTC.

Go to Step 18.

18 1. Remove the driver’s air mix motor assembly.

Refer to Section 2E, HVAC OCCUPANT

CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 19.

19 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem fixed?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 45 – PASSENGERS AIR MIX DOOR MOTOR FEEDBACK CIRCUIT VOLTAGE TOO LOW

Figure 2F-96

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, which moves the air mix door towards or away

from the heater core, the direction change takes place by reversi ng the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 45 will set when the feedback signal from the passenger air mix motor is short circuited for a period of 10

seconds.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks for faulty OCC.

This test checks for short to ground in circuit 705.

This test checks for a short in circuits 705 and 1236.

This test checks for a short in circuits 705 and 274.

This test checks that the resistance value of the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the resistance value of the potentiometer is not less than the minimum acceptable tolerance.

This test checks that the signal from the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the signal from the potentiometer is not less than minimum acceptable to lerance.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for sufficient power supply for the potentiometer from the OCC.

This test checks for short in circuits 705 or 61.

This test checks for short in circuits 61 or 2273.

This test checks for short in circuits 705 or 2273.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for open in circuits 61, 2273 and 705.

Ensures that DTC 40 has been cleared if present.

This test checks to see if the air mix door is physically jammed or bro ken.

This test determines whether the air mix motor a ssem bly is faulty.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 45 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 45 will be set again.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 45 – PASSENGERS AIR MIX DOOR MOTOR FEEDBACK CIRCUIT VOLTAGE TOO LOW DIAGNOSTIC

CHART

STEP ACTION VALUE YES

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness connector

A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data Display

/ Data List / Drivers Air Mix Door Feedback.

Does TECH 2 display a value above 3.4 volts?

– Go to Step 3. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. Install the passenger’s air mix motor (if

disconnected).

With the OCC connector A14 X2 disconnected,

probe OCC connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter and

chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705. Go to Step 4.

4 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-3, circuit 1236 (Brown wire) and

connector terminal X2-11, circuit 705 (White

wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705

and/or 1236.

Go to Step 5.

5 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-5, circuit 274 (Red / White wire)

and connector terminal X2-11, circuit 705

(White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 274

and/or 705.

Go to Step 6.

STEP ACTION VALUE YES

6 1. Disconnect the driver’s air mix motor

connector Y37 R X1. Less than

12 kilohms Go to Step 7. Go to Step 15.

7 In Step 6, was the value as specified? More than

8 kilohms Go to Step 8. Go to Step 12.

8 1. With the OCC connector A14 X2

disconnected, probe between OCC connector

terminal X2-11, circuit 705 (White wire) and

connector terminal X2-17, circuit 2273 (Yellow

/ Blue wire) with an ohmmeter.

Is the value as specified?

Less than

8.5 kilohms Go to Step 9. Go to Step 15.

9 In Step 8, was the value as specified? More than

1.5 kilohms Go to Step 10. Go to Step 12.

10 1. Inspect the OCC wiring harness connector

A14 X2 or air mix motor connector Y37 L X1

for an intermittent or loose terminal.

Are the connectors OK?

– Repair faulty

connector/s. Go to Step11.

11 1. Install the OCC connectors A14 X2 and

A14 X1.

Disconnect the passenger’s air mix motor

connector Y37 L X1.

Turn the ignition on

Probe the driver’s air mix motor connector Y37 R X1

between connector terminal X1-3 circuit 61 (Tan

wire) and connector terminal X1-1 circuit 705

(White wire) with a voltmeter.

Is the value as specified?

4.8 – 5.0

volts Go to Step 17. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C)–

REMOVAL &

INSTALLATION

12 1. Disconnect the air mix motor connectors

Y37 R X1 and Y37 L X1.

With the OCC connector A14 X2 disconnected,

probe between OCC connector terminal X2-11,

circuit 705 (White wire) and connector

terminal X2-15, circuit 61 (Tan wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705

and/or 61.

Go to Step 13.

13 1. With OCC connectors A14 X2 and Y37 L X1

disconnected, probe between OCC connector

terminal X2-15, circuit 61 (Tan wire) and

connector terminal X2-17, circuit 2273 (Yellow

/ Blue wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 61

and/or 2273.

Go to Step 14.

14 1. With OCC connectors A14 X2 and Y37 L X1

disconnected, probe between OCC connector

terminal X2-11, circuit 705 (White wire) and

connector terminal X2-17, circuit 2273 (Yellow

/ Blue wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as a

short.

0 Ohm Repair faulty

circuit 705

and/or 2273.

Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

STEP ACTION VALUE YES

15 1. Inspect the wiring harness connectors A14 X2

and Y37 L X1 for an intermittent or loose

terminal.

– Go to Step 16. Repair faulty

connector/s.

16 1. Check the integrity of circuits 61, 2273 and

705.

Are the circuits OK?

– Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

Repair faulty

circuits.

17 Is DTC 40 currently recorded in TECH 2? – Go to DTC 40 in

this Section and

clear DTC.

Go to Step 18.

18 1. Remove passenger’s air mix motor assembly.

Refer to Section 2E, HVAC OCCUPANT

CLIMATE CONTROL (AUTO A/C) –

REMOVAL & INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 19.

19 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem fixed?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 46 – PASSENGERS AIR MIX DOOR MOTOR FEEDBACK CIRCUIT ZOLTAGE TOO HIGH

Figure 2F-97

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, which moves the air mix door towards or away

from the heater core, the direction change takes place by reversi ng the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 46 will set when the feedback signal from the passenger air mix motor is short circuited for a period of 10

seconds.

Test Description:

1. Ensures the Diagnostic Circuit Check has been performed.

This test checks for faulty OCC.

This test checks for short to ground in circuit 705.

This test checks for a short in circuits 705 and 1236.

This test checks for a short in circuits 705 and 274.

This test checks that the resistance value of the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the resistance value of the potentiometer is not less than the minimum acceptable tolerance.

This test checks that the signal from the potentiometer does not exceed maximum acceptable tolerance.

This test checks that the signal from the potentiometer is not less than minimum acceptable to lerance.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for sufficient power supply for the potentiometer from the OCC.

This test checks for short in circuits 705 or 61.

This test checks for short in circuits 61 or 2273.

This test checks for short in circuits 705 or 2273.

This test checks for intermittent or loose terminals in the OCC an d air mix door motor connectors.

This test checks for open in circuits 61, 2273 and 705.

Ensures that DTC 40 has been cleared if present.

This test checks to see if the air mix door is physically jammed or bro ken.

This test determines whether the air mix motor a ssem bly is faulty.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 46 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 46 will be set again..

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for conne cting and using TECH 2.

DTC 46 – PASSENGERS AIR MIX DOOR MOTOR FEEDBACK CIRCUIT VOLTAGE TOO HIGH DIAGNOSTIC

CHART

STEP ACTION VALUE YES

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Disconnect the OCC wiring harness

connector A14 X2.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Data

Display / Data List / Drivers Air Mix Door

Feedback.

Does TECH 2 display a value above 3.4 volts?

– Go to Step 3. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

3 1. Install the passenger’s air mix motor (if

disconnected).

With the OCC connector A14 X2 disconnected,

probe OCC connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter to

chassis ground.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 705. Go to Step 4.

4 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-3, circuit 1236 (Brown

wire) and connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 705

and/or 1236.

Go to Step 5.

5 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-5, circuit 274 (Red /

White wire) and connector terminal X2-11,

circuit 705 (White wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 274

and/or 705.

Go to Step 6.

STEP ACTION VALUE YES

6 1. Disconnect the driver’s air mix motor

connector Y37 R X1. Less than

12 kilohms Go to Step 7. Go to Step 15.

7 In Step 6, was the value as specified? More than

8 kilohms Go to Step 8. Go to Step 12.

8 1. With the OCC connector A14 X2

disconnected, probe between OCC

connector terminal X2-11, circuit 705 (White

wire) and connector terminal X2-17,

circuit 2273 (Yellow / Blue wire) with an

ohmmeter.

Is the value as specified?

Less than

8.5 kilohms Go to Step 9. Go to Step 15.

9 In Step 8, was the value as specified? More than

1.5 kilohms Go to Step 10. Go to Step 12.

10 1. Inspect the OCC wiring harness connector

A14 X2 or air mix motor connector Y37 L X1

for an intermittent or loose terminal.

Are the connectors OK?

– Repair faulty

connector/s. Go to Step11.

11 1. Install the OCC connectors A14 X2 and

A14 X1 to OCC control module.

Disconnect passenger’s air mix motor connector

Y37 L X1.

Turn the ignition on

Measure voltage at driver’s air mix motor

connector Y37 R X1 between OCC connector

terminal X1-3 circuit 61 (Tan wire) and

connector terminal X1-1 circuit 705 (White

wire).

Is the value as specified?

4.8 – 5.0

volts Go to Step 17. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C)–

REMOVAL &

INSTALLATION

12 1. Disconnect the air mix motor connectors

Y37 R X1 and Y37 L X1.

With the OCC connector A14 X2 disconnected,

probe between OCC connector terminal X2-11,

circuit 705 (White wire) and connector terminal

X2-15, circuit 61 (Tan wire) with an ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 705

and/or 61.

Go to Step 13.

13 1. With OCC connectors A14 X2 and Y37 L X1

disconnected, probe between OCC

connector terminal X2-15, circuit 61 (Tan

wire) and connector terminal X2-17,

circuit 2273 (Yellow / Blue wire) with an

ohmmeter.

Is the value as specified?

NOTE: Any resistance measured here qualifies as

a short.

0 Ohm Repair faulty

circuit 61

and/or 2273.

Go to Step 14.

STEP ACTION VALUE YES

14 1. With OCC connectors A14 X2 and Y37 L X1

disconnected, probe between OCC

connector terminal X2-11, circuit 705 (White

wire) and connector terminal X2-17,

circuit 2273 (Yellow / Blue wire) with an

ohmmeter.

0 Ohm Repair faulty

circuit 705

and/or 2273.

Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

15 1. Inspect wiring harness connectors A14 X2

and Y37 L X1 for an intermittent or loose terminal.

Are the connectors OK?

– Go to Step 16. Repair faulty

connector/s.

16 1. Check the integrity of circuits 61, 2273 and

705.

Are the circuits OK?

– Repair faulty

circuits. Replace the air

mix door motor.

Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

17 Is DTC 40 currently recorded in TECH 2? – Go to DTC 40 in

this Section and

clear DTC.

Go to Step 18.

18 1. Remove the passenger’s air mix motor

assembly, refer to Section 2E, HVAC

OCCUPANT CLIMATE CONTROL (AUTO

A/C) – REMOVAL & INSTALLATION.

Move the air mix door by hand.

Is the door physically jammed or bro ken ?

– Repair faulty air

mix door. Go to Step 19.

19 1. Replace the air mix motor assembly. Refer to

Section 2E, HVAC OCCUPANT CLIMATE

CONTROL (AUTO A/C) – REMOVAL &

INSTALLATION.

Is the problem fixed?

– System OK. Replace the

OCC control

module. Refer to

Section 2E,

HVAC

OCCUPANT

CLIMATE

CONTROL

(AUTO A/C) –

REMOVAL &

INSTALLATION

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 47 – DRIVER AIR MIX MIN. CALIBRATIO N ERROR ( LHD)

Figure 2F-98

Circuit Description:

The air mix motor is an electric motor used to operate the air mix doors. The electric motor is sent a voltage signal

of 12.5 volts from the OCC module which causes the motor to turn, which moves the air mix doors towards or away

from the heater core, the direction change takes place by reversi ng the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 47 will set: if the PBR feedback signal fails to reach the requested value. This will occur if the PBR or motor is

open or short circuited, or an air mix door is jammed or sticking.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the DTC is current.

3. This test checks if the motor is moving.

4. This test checks that the motor is stopping within the correct range at full cold.

5. This test checks that the motor is stopping within the correct range at full hot.

6. Attempts to recalibrate and check DTC is still current.

7. Determines if a PBR fault is the likely cause of the problem.

8. Determines if a motor fault is more likely than a PBR fault to be the cause of the problem.

9. Checks fault has been rectified.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 47 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 47 will be set again.

DTC 47 – DRIVER AIR MIX MIN. CALIBRATIO N ERR OR ( LHD) DIAGNOSTIC CHART

STEP ACTION VALUE YES

1 Has the Diagnostic Circuit Check been performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Turn the ignition off.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Diagnostic

Trouble Codes / Read Current DTC Information.

Does DTC 47 display a s the cur re nt DTC?

– Go to Step 3. Go to Step 9.

3 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Drivers Side Air Mix Motor – Door

Movement.

Move the air mix door maximum then decrease to

minimum.

Does the TECH 2 value change accordingly?

– Go to Step 4. Go to Step 7.

4 1. With the Drivers Side Air Mix Motor – Door

Movement test selected, decrease the air mix

door to minimum.

Does TECH 2 display a value within 0.6 – 0.9 volt?

– Go to Step 5. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (LHD)

in this Section.

5 1. With the Drivers Side Air Mix Motor – Door

Movement test selected, increase the air mix

door to maximum.

Does TECH 2 display a value within 2.6 – 2.9 volts?

– Go to Step 6. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (LHD)

in this Section.

6 1. With TECH 2 connected, select Body /

Occupant Climate Control / Program /

Calibrate Air Mix Door.

Reprogram the air mix door.

Turn the ignition off.

Turn the ignition on.

Does DTC 47 set as the cu rrent DTC?

– Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (LHD)

in this Section.

Go to Step 9.

7 In Step 3, did TECH 2 display less than 0.3 volt? – Go to chart

DTC 43 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

(LHD) in this

Section.

Go to Step 8.

STEP ACTION VALUE YES

8 In Step 3, did TECH 2 display more than 3.4 volts? 3.4 volts Go to chart

DTC 44 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH (LHD) in

this Section.

Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (LHD)

in this Section.

9 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Drivers Side Air Mix Motor– Door

Movement.

Increase to maximum then decrease to minimum.

Does DTC 47 set as a current DTC?

– Go to Step 3. Recalibration of

Air mix door

may have

corrected fault

or DTC 47 is

intermittent.

(Carry out air

mix door

calibration if not

already done

so. Refer to 1.2

TECH 2 TEST

MODES AND

DISPLAYS

FOR OCC

DIAGNOSIS

and/or refer to

2 DIAGNOSTIC

CHARTS in this

Section.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 47 – DRIVER AIR MIX MIN. CALIBRATION ERROR (RHD)

Figure 2F-99

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, which moves the air mix door towards or away

from the heater core, the direction change takes place by reversi ng the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 47 will set: if the drivers PBR feedback signal fails to reach the requested value. This will occur if the PBR or

motor is open or short circu ited, or if the air mix door is jammed or sticking.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the DTC is current.

3. This test checks if the motor is moving.

4. This test checks that the motor is stopping within the correct range at full cold.

5. This test checks that the motor is stopping within the correct range at full hot.

6. Attempts to recalibrate and check DTC is still current.

7. Determines if a PBR fault is the likely cause of the problem.

8. Determines if a motor fault is more likely than a PBR fault to be the cause of the problem.

9. Checks fault has been rectified.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 47 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 47 will be set again.

DTC 47 – DRIVER AIR MIX MIN. CALI BRATION ERROR (RHD) DIAGNOSTI C C HA RT

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Turn the ignition off.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Diagnostic

Trouble Codes / Read Current DTC Information.

Does DTC 47 display a s the cur re nt DTC?

– Go to Step 3. Go to Step 9.

3 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Drivers Side Air Mix Motor – Door

Movement.

Increase to maximum then decrease to minimum.

Does the TECH 2 value change accordingly?

– Go to Step 4. Go to Step 7.

4 1. With Drivers Side Air Mix Motor – Door

Movement test selected, decrease the air mix

door to minimum.

Does TECH 2 display a value within 0.6 – 0.9 volt?

– Go to Step 5. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

DRIVERS SIDE

MOTOR) in this

Section.

5 1. With Drivers Side Air Mix Motor – Door

Movement test selected increase the air mix

door to maximum.

Does TECH 2 display a value within 2.6 to 2.9 volts?

– Go to Step 6. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

DRIVERS SIDE

MOTOR) in this

Section.

6 1. With TECH 2 connected, select Body /

Occupant Climate Control / Program /

Calibrate Air Mix Door.

Reprogram the air mix doors.

Turn the ignition off.

Turn the ignition on.

Does DTC 47 set as a current DTC?

– Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

DRIVERS SIDE

MOTOR) in this

Section.

Go to Step 9.

STEP ACTION VALUE YES NO

7 In Step 3, did TECH 2 display less than 0.3 volt? – Go to chart

DTC 43 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

in this Section .

Go to Step 8

8 In Step 3, did TECH 2 display more than 3.4 volts? – Go to chart

DTC 44 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH in this

Section .

Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

DRIVERS SIDE

MOTOR) in this

Section.

9 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Drivers Side Air Mix Motor– Door

Movement.

Increase to maximum then decrease to minimum.

Does DTC 47 set as a current DTC?

– Go to Step 3. Recalibration of

Air mix door

may have

corrected fault

or DTC 47 is

intermittent.

(Carry out air

mix door

calibration if not

already done

so. Refer to 1.2

TECH 2 TEST

MODES AND

DISPLAYS

FOR OCC

DIAGNOSIS

and/or refer to

2 DIAGNOSTIC

CHARTS in this

Section.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 48 – DRIVER AIR MIX MAX. CALIBRATIO N ERROR ( LHD)

Figure 2F-100

Circuit Description:

The air mix motor is an electric motor used to operate the air mix doors. The electric motor is sent a voltage signal

of 12.5 volts from the OCC module which causes the motor to turn, which moves the air mix doors towards or away

from the heater core, the direction change takes place by reversi ng the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 48 will set: if the PBR feedback signal fails to reach the requested value. This will occur if the PBR or motor is

open or short circuited, or an air mix door is jammed or sticking.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the DTC is current.

3. This test checks if the motor is moving.

4. This test checks that the motor is stopping within the correct range at full cold.

5. This test checks that the motor is stopping within the correct range at full hot.

6. Attempts to recalibrate and check DTC is still current.

7. Determines if a PBR fault is the likely cause of the problem.

8. Determines if a motor fault is more likely than a PBR fault to be the cause of the problem.

9. Checks fault has been rectified.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

2. Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 48 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 48 will be set again.

DTC 48 – DRIVER AIR MIX MAX. CALI BRATION ERROR (LHD) DIAGNOSTIC CHART

STEP ACTION VALUE YES

1 Was the Diagnostic Circuit Check performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Turn the ignition off.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Diagnostic

Trouble Codes / Read Current

DTC Information.

Does DTC 48 display a s a current DTC?

– Go to Step 3. Go to Step 9.

3 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Drivers Side Air Mix Motor – Door

Movement

Increase to maximum then decrease to minimum.

Does the TECH 2 value change accordingly?

– Go to Step 4. Go to Step 7.

4 With Drivers Side Air Mix Motor – Door Movement

test still selected, decrease air mix door to

minimum.

Does TECH 2 display a value within 0.6 – 0.9 volt?

– Go to Step 5. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (LHD)

in this Section.

5 1. With Drivers Side Air Mix Motor – Door

Movement test still selected increase air mix

door to maximum.

Does TECH 2 display a value within 2.6 to 2.9

volts?

– Go to Step 6. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (LHD)

in this Section.

6 1. With TECH 2 connected, select Body /

Occupant Climate Control / Program /

Calibrate Air Mix Door.

Reprogram the air mix door.

Turn the ignition off.

Turn the ignition on.

Does DTC 48 set as a current DTC?

– Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (LHD)

in this Section.

Go to Step 9.

7 In Step 3, did TECH 2 display less than 0.3 volt? – Go to chart

DTC 43 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

(LHD) in this

Section .

Go to Step 8.

STEP ACTION VALUE YES

8 In Step 3, did TECH 2 display more than 3.4 volts? – Go to chart

DTC 44 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH (LHD) in

this Section .

Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (LHD)

in this Section.

9 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Drivers Side Air Mix Motor– Door

Movement.

Increase to maximum then decrease to minimum.

Does DTC 48 set as a current DTC?

– Go to Step 3. Recalibration of

Air mix door

may have

corrected fault

or DTC 48 is

intermittent.

(Carry out air

mix door

calibration if not

already done

so. Refer to 1.2

TECH 2 TEST

MODES AND

DISPLAYS

FOR OCC

DIAGNOSIS

and/or refer to

2 DIAGNOSTIC

CHARTS in this

Section.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 48 – DRIVER AIR MIX MAX. CALIBRATION ERROR (RHD)

Figure 2F-101

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, which moves the air mix door towards or away

from the heater core, the direction change takes place by reversi ng the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 48 will set: if the drivers PBR feedback signal fails to reach the requested value. This will occur if the PBR or

motor is open or short circu ited, or if the air mix door is jammed or sticking.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the DTC is current.

3. This test checks if the motor is moving.

4. This test checks that the motor is stopping within the correct range at full cold.

5. This test checks that the motor is stopping within the correct range at full hot.

6. Attempts to recalibrate and check DTC is still current.

7. Determines if a PBR fault is the likely cause of the problem.

8. Determines if a motor fault is more likely than a PBR fault to be the cause of the problem.

9. Checks fault has been rectified.

Notes on Diagnostic Chart:

1. Refer to 5. WIRING DIAGRAMS in this Section for views of OCC system related electrical connectors and

complete OCC system wiring diag rams.

For electrical connector locations and additional wiring diagram information, refer to

Section 12P WIRING DIAGRAMS

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 48 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 48 will be set again.

DTC 48 – DRIVER AIR MIX MAX. CALI BRATION ERROR (RHD) DIAGNOSTI C C HA RT

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check performed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Turn the ignition off.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Diagnostic

Trouble Codes / Read Current DTC Information.

Does DTC 48 display as a the current DTC?

– Go to Step 3. Go to Step 9.

3 1. With TECH 2 connected, select Diagnostics /

Model Year / Vehicle Model / Body / Occupant

Climate Control / Miscellaneous Tests / Drivers

Side Air Mix Motor – Door Movement.

Increase to maximum then decrease to minimum.

Does the TECH 2 value change accordingly?

– Go to Step 4. Go to Step 7.

4 1. With Drivers Side Air Mix Motor – Door

Movement test still selected, decrease air mix

door to minimum.

Does TECH 2 display a value within 0.6 – 0.9 volt?

– Go to Step 5. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

DRIVERS SIDE

MOTOR) in this

Section.

5 1. With Drivers Side Air Mix Motor – Door

Movement test still selected increase air mix

door to maximum.

Does TECH 2 display a value within 2.6 to 2.9 volts?

– Go to Step 6. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

DRIVERS SIDE

MOTOR) in this

Section.

6 1. With TECH 2 connected, select Body /

Occupant Climate Control / Program /

Calibrate Air Mix Door.

Reprogram the air mix doors.

Turn the ignition off.

Turn the ignition on.

Does DTC 48 set as a current DTC?

– Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

DRIVERS SIDE

MOTOR) in this

Section.

Go to Step 9.

7 In Step 3, did TECH 2 display less than 0.3 volt? – Go to chart

DTC 43 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

in this Section .

Go to Step 8.

STEP ACTION VALUE YES NO

8 In Step 3, did TECH 2 display more than 3.4 volts? – Go to chart

DTC 44 –

DRIVERS AIR

MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH in this

Section.

Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

DRIVERS SIDE

MOTOR) in this

Section.

9 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Drivers Side Air Mix Motor– Door

Movement.

Increase to maximum then decrease to minimum.

Does DTC 48 set as a current DTC?

– Go to Step 3. Recalibration of

Air mix door

may have

corrected fault

or DTC 48 is

intermittent.

(Carry out air

mix door

calibration if not

already done

so. Refer to 1.2

TECH 2 TEST

MODES AND

DISPLAYS

FOR OCC

DIAGNOSIS

and/or refer to

2. DIAGNOSTI

C CHARTS in

this Section.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION

DTC 49 – PASS AIR MIX MIN. CALIBRATION ER ROR

Figure 2F-102

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, which moves the air mix door towards or away

from the heater core, the direction change takes place by reversi ng the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (5.0 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 49 will set: if the passengers PBR feedback signal fails to reach the requested value. This will occur if the

PBR or motor is open or short circuited, or it the air mix door is jammed or sticki ng.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the DTC is current.

3. This test checks if the motor is moving.

4. This test checks that the motor is stopping within the correct range at full cold.

5. This test checks that the motor is stopping within the correct range at full hot.

6. Attempts to recalibrate and check DTC is still current.

7. Determines if a PBR fault is the likely cause of the problem.

8. Determines if a motor fault is more likely than a PBR fault to be the cause of the problem.

9. Checks fault has been rectified.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum value

are considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 49 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 49 will be set again.

DTC 49 – PASS AIR MIX MIN. CALIBRATION ERROR DIAGNOSTIC CHART

STEP ACTION VALUE YES NO

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Turn the ignition off.

Connect TECH 2 to the DLC.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Diagnostic

Trouble Codes / Read Current

DTC Information.

Does DTC 49 display a s the current DTC?

– Go to Step 3. Go to Step 9.

3 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Passenger Side Air Mix Motor – Door

Movement and increase to maximum then

decrease to minimum.

Does the TECH 2 value change accordingly?

– Go to Step 4. Go to Step 7.

4 1. With Passengers Side Air Mix Motor – Door

Movement test still selected, decrease air mix

door to minimum.

Does TECH 2 display a value within 0.6 – 0.9 volt?

– Go to Step 5. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

PASSENGERS

SIDE MOTOR)

in this Section.

5 1. With Passengers Side Air Mix Motor – Door

Movement test still selected increase air mix

door to maximum.

Does TECH 2 display a value within 2.6 to 2.9

volts?

– Go to Step 6. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

PASSENGERS

SIDE MOTOR)

in this Section.

6 1. With TECH 2 connected, select Body /

Occupant Climate Control / Program /

Calibrate Air Mix Door.

Reprogram the air mix doors.

Turn the ignition off.

Turn the ignition on.

Does DTC 24 set as a current DTC?

– Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

PASSENGERS

SIDE MOTOR)

in this Section.

Go to Step 9.

7 In Step 3, did TECH 2 display less than 0.3 volt? – Go to chart

DTC – 45

PASSENGERS

AIR MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

in this Section.

Go to Step 8.

STEP ACTION VALUE YES NO

8 In Step 3, did TECH 2 display more than 3.4 volts? – Go to chart

DTC – 46

PASSENGERS

AIR MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH in this

Section.

Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

PASSENGERS

SIDE MOTOR)

in this Section.

9 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Passengers Side Air Mix Motor– Door

Movement.

Increase to maximum then decrease to minimum.

Does DTC 49 set as a current DTC?

– Go to Step 3. Recalibration of

Air mix door

may have

corrected the

fault or DTC 49

is intermittent.

(Carry out air

mix door

calibration if not

already done

so. Refer to 1.2

TECH 2 TEST

MODES AND

DISPLAYS

FOR OCC

DIAGNOSIS

and/or refer to

2. DIAGNOSTI

C CHARTS in

this Section.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR ALL D TC AND VERIFY CORRECT

OPERATION

DTC 50 – PASS AIR MIX MAX. CALIBRATION ERRO R

Figure 2F-103

Circuit Description:

The air mix motor is an electric motor used to operate the air mix door. The electric motor is sent a voltage signal of

12.5 volts from the OCC module which causes the motor to turn, which moves the air mix door towards or away

from the heater core, the direction change takes place by reversi ng the polarity of this motor.

A potentiometer (PBR) is housed in the air mix motor circuit, which feeds signals (3.6 ± 0.18 volts) back to the OCC

module as to the positioning of the motor and consequently the air mix door.

DTC 50 will set: if the passengers PBR feedback signal fails to reach the requested value. This will occur if the

PBR or motor is open or short circuited, or it the air mix door is jammed or sticki ng.

Test Description:

Number(s) below refer to Step numbers in the followin g Diagnostic Chart:

1. Ensures the Diagnostic Circuit Check has been performed.

2. This test checks that the DTC is current.

3. This test checks if the motor is moving.

4. This test checks that the motor is stopping within the correct range at full cold.

5. This test checks that the motor is stopping within the correct range at full hot.

6. Attempts to recalibrate and check DTC is still current.

7. Determines if a PBR fault is the likely cause of the problem.

8. Determines if a motor fault is more likely than a PBR fault to be the cause of the problem.

9. Checks fault has been rectified.

Notes on Diagnostic Chart:

1. Refer to Section 12P, WIRING DIAGRAMS for procedures on checking wiring faults.

Refer to 1.1 TECH 2 DIAGNOSTICS in this Section for connecting and using TECH 2.

Diagnostic Aids:

An air mix motor or door problem will always be associated with non-regulated or incorrect temperatures from

mode positions.

The OCC control module, during calibration, sets a minimum and a maximum PBR value for the air mix motor in its

memory. It is these values which determine the operating range of the air mix motor and against which all

movements of the air mix adjustment are scaled. Any PBR signal value outside the minimum or maximum vale are

considered a motor fault.

The OCC module monitors the rate of change of PBR signal during air mix motor movement. If this rate of change

falls to 0 (such as a broken air mix motor wire or physical jamb), the OCC module will recognise the stoppage and

set the fault code.

If DTC 50 was present before turning the ignition off, when the ignition is turned on again, the OCC module will

automatically try to recalibrate the air mix door. This takes approximately 15 seconds. If the recalibration fails, then

DTC 50 will be set again.

DTC 50 – PASS AIR MIX MAX. CALIBRATION ERROR DIAGNOSTIC CHART

STEP ACTION VALUE YES

1 Was the Diagnostic Circuit Check perfo rmed? – Go to Step 2. Go to Chart A –

DIAGNOSTIC

CIRCUIT

CHECK in this

Section.

2 1. Turn the ignition off.

Connect TECH 2 to the DLC.

Turn the ignition on when instructed by TECH 2.

Select Diagnostics / Model Year / Vehicle Model /

Body / Occupant Climate Control / Diagnostic

Trouble Codes / Read Current

DTC Information.

Does DTC 50 display a s the current DTC?

– Go to Step 3. Go to Step 9.

3 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Passenger Side Air Mix Motor – Door

Movement.

Increase to maximum then decrease to minimum.

Does the TECH 2 value change accordingly?

– Go to Step 4. Go to Step 7.

4 1. With Passengers Side Air Mix Motor – Door

Movement test still selected, decrease air mix

door to minimum.

Does TECH 2 display a value within 0.6 – 0.9 volt?

– Go to Step 5. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

PASSENGERS

SIDE MOTOR)

in this Section.

5 1. With Passengers Side Air Mix Motor – Door

Movement test still selected increase air mix

door to maximum.

Does TECH 2 display a value within 2.6 to 2.9

volts?

– Go to Step 6. Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

PASSENGERS

SIDE MOTOR)

in this Section.

6 1. With TECH 2 connected, select Body /

Occupant Climate Control / Program /

Calibrate Air Mix Door.

Reprogram the air mix doors.

Turn the ignition off.

Turn the ignition on.

Does DTC 24 set as a current DTC?

– Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

PASSENGERS

SIDE MOTOR)

in this Section.

Go to Step 9.

7 In Step 3, did TECH 2 display less than 0.3 volt? – Go to chart

DTC – 45

PASSENGERS

AIR MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO LOW

in this Section.

Go to Step 8.

STEP ACTION VALUE YES

8 In Step 3, did TECH 2 display more than 3.4 volts? – Go to chart

DTC – 46

PASSENGERS

AIR MIX DOOR

MOTOR

FEEDBACK

CIRCUIT VOLT

AGE TOO

HIGH in this

Section.

Go to chart

DTC 40 – AIR

MIX DOOR

MOTOR

DRIVER

ERROR (RHD

PASSENGERS

SIDE MOTOR)

in this Section.

9 1. With TECH 2 connected, select Body /

Occupant Climate Control / Miscellaneous

Tests / Passengers Side Air Mix Motor– Door

Movement.

Increase to maximum then decrease to minimum.

Does DTC 50 set as a current DTC?

– Go to Step 3. Recalibration of

the Air mix door

may have

corrected fault

or DTC 50 is

intermittent.

(Carry out air

mix door

calibration if not

already done

so. Refer to 1.2

TECH 2 TEST

MODES AND

DISPLAYS

FOR OCC

DIAGNOSIS

and/or refer to

2. DIAGNOSTI

C CHARTS in

this Section.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR ALL D TC AND VERIFY CORRECT

OPERATION

3. ELECTRICAL COMPONENT TESTS

3.1 IN CAR TEMPERATURE SENSOR

To test the in car temperature sensor, use an

ohmmeter to check for resistance across the

terminals on either the sensor or the O C C module

connector.

Refer to Figure 2F-104 in conjunction with the

following tables for details of the pin numbers an d

resistances.

Perform the test as follows:

1. Remove the in-car temperature sensor or OCC

connector. Refer to Section 2E, HVAC Occupant

Climate Control (Auto A/C) – Removal and

Installation.

2. Position the contacts of the ohmmeter on the

terminals and take the reading while noting the

temperature at the sensor.

3. Using a digital thermometer, placed as close to

the in car temperature sensor as possible,

compare thermometer reading with the ohmmeter

reading Compare the reading with the table

(should be within ± 3°C).

4. If the in car temperature sensor fails any part of

the test, replace the sensor with a serviceable

item.

5. Install the in-car temperature sensor, refer to

Section 2E, HVAC Occupant Climate Control

(Auto A/C) – Removal and Installation.

B59 CONNECTOR DETAI LS

PIN NUMBER FUNCTION

X1-A Ground

X1-B Power from OCC

A14 X1 CONNECTOR DETAILS

PIN NUMBER FUNCTION

X1-2 Ground

X1-10 2.5 V Power

Figure 2F-104

IN CAR AIR TEMPERATURE° C RESISTANCE Ω

5 7009 – 7536

10 5477 – 5856

15 4310 – 4583

20 3416 – 3612

25 2725 – 2865

30 2175 – 2299

35 1746 – 1857

40 1410 – 1508

45 1145 – 1231

50 935 – 1010

3.2 EVAPORATIVE TEMPERATURE SENSOR TEST

LEFT-HAND DRIVE

To test the evaporative temperature sensor, use an

ohmmeter to check for resistance across the

terminals on either the sensor or O CC module

connector.

Refer to Figure 2F-105 in conjunction with the

following tables for details of the pin numbers an d

resistances.

Perform the test as follows:

1. Remove the evaporative temperature sensor or

OCC connector. Refer to Section 2E, HVAC

Occupant Climate Control (Auto A/C) – Removal

and Installation.

2. Position the contacts of the ohmmeter on the

terminals and take the reading while noting the

temperature at the sensor.

3. Using a digital thermometer, placed as close to

the evaporative temperature sensor as possible,

compare thermometer reading with the ohmmeter

reading. Compare the reading with the table

(should be within ± 3°C). Temperature readings

should be about 2 – 8°C higher than TECH 2

readings.

4. If the evaporative temperature sensor fails any

part of the test, replace the sensor with a

serviceable item.

5. Install the evaporative temperature sensor or

OCC connector, refer to Section 2E, HVAC

Occupant Climate Control (Auto A/C) – Removal

and Installation.

B34 CONNECTOR DETAI LS

PIN NUMBER FUNCTION

X1-1 Power from OCC

X1-2 Ground

A14 X2 CONNECTOR DETAILS

PIN NUMBER FUNCTION

X2-15 Ground

X2-19 2.5 V Power

Figure 2F-105

EVAPORATIVE

AIR TEMPERATURE°C RESISTANCE Ω

5 4300 – 4850

10 3600 – 4050

15 2950 – 3250

20 2320 – 2625

25 1990 – 2200

30 1675 – 1850

35 1330 – 1470

40 1140 – 1260

45 950 – 1050

50 850 – 950

RIGHT-HAND DRIVE

To test the evaporative temperature sensor, use an

ohmmeter to check for resistance across the

terminals on either the sensor or O CC module

connector.

Refer to Figure 2F-106 in conjunction with the

following tables for details of the pin numbers an d

resistances.

Perform the test as follows:

1. Remove the evaporative temperature sensor or

OCC connector. Refer to Section 2E, HVAC

Occupant Climate Control (Auto A/C) – Removal

and Installation.

2. Position the contacts of the ohmmeter on the

terminals and take the reading while noting the

temperature at the sensor.

3. Using a digital thermometer, placed as close to

the evaporative temperature sensor as possible,

compare thermometer reading with the ohmmeter

reading. Compare the reading with the table

(should be within ± 3°C). Temperature readings

should be about 2 – 8°C higher than TECH 2

readings.

4. If the evaporative temperature sensor fails any

part of the test, replace the sensor with a

serviceable item.

5. Install the evaporative temperature sensor or

OCC connector. Refer to Section 2E, HVAC

Occupant Climate Control (Auto A/C) – Removal

and Installation.

B34 CONNECTOR DETAI LS

PIN NUMBER FUNCTION

X1-A Power from OCC

X1-B Ground

A14 X2 CONNECTOR DETAILS

PIN NUMBER FUNCTION

X2-15 Ground

X2-19 2.5 V Power

Figure 2F-106

EVAPORATIVE

AIR TEMPERATURE°C RESISTANCE Ω

5 4300 – 4850

10 3600 – 4050

15 2950 – 3250

20 2320 – 2625

25 1990 – 2200

30 1675 – 1850

35 1330 – 1470

40 1140 – 1260

45 950 – 1050

50 850 – 950

3.3 AMBIENT TEMPERATURE SENSOR

To test the ambient temperature sensor, use an

ohmmeter to check for resistance across the

terminals on either the sensor or O CC module

connector.

Refer to Figure 2F-107 in conjunction with the

following tables for details of the pin numbers an d

resistances.

Perform the test as follows:

1. Remove the ambient temperature sensor or OCC

connector. Refer to Section 2E, HVAC Occupant

Climate Control (Auto A/C) – Removal and

Installation.

2. Position the contacts of the ohmmeter on the

terminals and take the reading while noting the

temperature at the sensor. Compare the reading

with the table.

3. Using a digital thermometer, placed as close to

the ambient temperature sensor as possible,

compare thermometer reading with the ohmmeter

reading. Compare the reading with the table

(should be within ± 3°C). Temperature readings

should be within ± 3°C of TECH 2 readings.

4. If the ambient temperature sensor fails any part of

the test, replace the sensor with a serviceable

item.

5. Install the ambient temperature sensor or OCC

connector. Refer to Section 2E, HVAC Occupant

Climate Control (Auto A/C) – Removal and

Installation.

B23 CONNECTOR DETAI LS

PIN NUMBER FUNCTION

X1-A Ground

X1-B Power from OCC

Figure 2F-107

A14 X1 CONNECTOR DETAILS

PIN NUMBER FUNCTION

X1–2 Ground

X1–12 2.5 V Power

AMBIENT AIR

TEMPERATURE°C RESISTANCE Ω

0 15920 – 16750

10 9715 – 10193

20 6107 – 6389

30 3943 – 4115

40 2610 – 2717

50 1767 – 1836

60 1201 – 1291

3.4 OCC BLOWER MOTOR RESISTOR

LEFT-HAND DRIVE

To test the blower motor resistor, use an ohmmeter

to check for resistance across the different

terminals.

Refer to Figure 2F-108 in conjunction with the

following tables for details of the pin numbers an d

resistances.

Perform the test as follows:

1. Remove the blower motor resistor. Refer to

Section 2B, 7 BLOWER MOTOR RESISTOR.

2. Position the contacts of the ohmmeter on the

terminals and take the reading. Compare the

reading with the table.

3. If there is continuity between any other

terminals other than those listed, the blower

motor resistor is faulty. If blower motor resistor

fails any part of the test, replace the resistor

with a serviceable item.

4. Install the blower motor resistor. Refer to

Section 2B, 7 BLOWER MOTOR RESISTOR.

A13_LHD CONNECTO R DETAILS

PIN NUMBER FUNCTION

X1-1 Fan Spd Cont

X1-2 Not Connected

X1-3 Ground

X1-4 Blower Motor

Figure 2F-108

CONTROLLER CONTACTS

AND METER POLARITIES RESISTANCE Ω

X1-1 and X1-3 2.9

X1-1 +ve and X1-4 –ve 1.5

X1-1 –ve and X1-4 +ve 1.5

X1-4 +ve and X1-3 -ve 1.5

X1-4 –ve and X1-3 +ve 1.5

RIGHT-HAND DRIVE

To test the blower motor resistor, use an ohmmeter

to check for resistance across the different

terminals.

Refer to Figure 2F-109 in conjunction with the

following tables for details of the pin numbers an d

resistances.

Perform the test as follows:

1. Remove the blower motor resistor. Refer to

Section 2B, 7 BLOWER MOTOR RESISTOR.

2. Position the contacts of the ohmmeter on the

terminals and take the reading. Compare the

reading with the table.

3. If there is continuity between any other

terminals other than those listed, the blower

motor resistor is faulty. If the blower motor

resistor fails any part of the test, replace the

resistor with a servicea ble item.

4. Install the blower motor resistor. Refer to

Section 2B, 7 BLOWER MOTOR RESISTOR.

A13_RHD CONNECTOR DETAILS

PIN NUMBER FUNCTION

X1-1 Fan Spd Cont

X1-2 Not Connected

X1-3 Blower Motor

X1-4 Not Connected

X1-5 Not Connected

X1-6 Ground

Figure 2F-109

CONTROLLER CONTACTS

AND METER POLARITIES RESISTANCE Ω

X1-1 and X1-6 2.0

X1-1 +ve and X1-3 –ve 1.3

X1-1 –ve and X1-3 +ve 1.3

X1-3 +ve and X1-6 –ve 1.0

X1-3 –ve and X1-6 +ve 0.9

3.5 VACUUM SOLENOID PACK

LEFT-HAND DRIVE

To test the OCC solenoid pack, use an ohmmeter

to check for resistance across the different

terminals.

Refer to Figure 2F-left-hand drive in conjunctio n

with the following tables for details of the pin

numbers and resistan ces.

Perform the test as follows:

1. Remove the solenoid pack, refer to the LHD

information in Section 2E, 2.7 VACUUM

SOLENOID PACK.

2. Position the contacts of the ohmmeter on the

terminals and take the reading. Compare the

reading with the table.

3. If resistance reading are not to specification or

there is continuity between any other terminals

other than those listed, the solenoid pack is

faulty. If the solenoid pack fails any part of the

test, replace the complete solenoid pack.

4. Install the vacuum solenoid pack, refer to the

LHD information in Section 2E, 2.7 VACUUM

SOLENOID PACK.

Y19_LHD CONNECTOR DETAILS

PIN NUMBER FUNCTION

X1-1 12 V power

X1-2 Solenoid 5 – Intake

X1-3 Solenoid 4 – Face 1

X1-4 Solenoid 3 – Face 2

X1-5 Solenoid 2 – Defog

X1-6 Solenoid 1 – Foot

Figure 2F-110

SOLENOID PACK CONTACTS RESISTANCE Ω

X1-1 and X1-2 89 – 91

X1-1 and X1-3 89 – 91

X1-1 and X1-4 89 – 91

X1-1 and X1-5 89 – 91

X1-1 and X1-6 89 – 91

RIGHT-HAND DRIVE

To test the OCC solenoid pack, use an ohmmeter

to check for resistance across the different

terminals.

Refer to Figure 2F-111 in conjunction with the

following tables for details of the pin numbers an d

resistances.

Preform the test as follows:

1. Remove the solenoid pack, refer to the RHD

information in Section 2E, 2.7 VACUUM

SOLENOID PACK.

2. Position the contacts of the ohmmeter on the

terminals and take the reading. Compare the

reading with the table.

3. If resistance reading are not to specification or

there is continuity between any other terminals

other than those listed, the solenoid pack is

faulty. If the solenoid pack fails any part of the

test, replace the complete solenoid pack.

4. Install the vacuum solenoid pack, refer to the

RHD information in Section 2E, 2.7 VACUUM

SOLENOID PACK.

Y19_RHD CONNECTOR DETAILS

PIN NUMBER FUNCTION

X1-1 Solenoid 4 – Foot 1

X1-2 Solenoid 2 – Face 1

X1-3 Solenoid 1 – Intake

X1-4 12 V Power

X1-5 Solenoid 6 – Water

X1-6 Solenoid 2 – Face 2

X1-7 Solenoid 5 – Foot 2

X1-8 Not Connected

Figure 2F-111

SOLENOID PACK CONTACTS RESISTANCE Ω

X1-4 and X1-1 109 – 111

X1-4 and X1-2 109 – 111

X1-4 and X1-3 109 – 111

X1-4 and X1-5 109 – 111

X1-4 and X1-6 109 – 111

X1-4 and X1-7 109 – 111

3.6 WATER VALVE VACUUM SWITCH VALVE

NOTE: The water valve vacuum switch valve is fitted

to LHD type OCC (Auto A/C) HVAC units only.

To test the water valve vacuum switch valve, use an

ohmmeter to check for resistance across the

terminals.

Refer to Figure 2F-112 in conjunction with the

following tables for details of the pin numbers an d

resistances.

Perform the test as follows:

1. Remove the water valve vacuum switch valve.

Refer to Section 2E, 2.8 WATER VALVE

VACUUM SWITCH VALVE.

2. Position the contacts of the ohmmeter on the

terminals and take the reading. Compare the

reading with the table.

3. If the switch valve fails any part of the test,

replace the switch with a serviceable item .

4. Install the water valve vacuum switch valve.

Refer to Section 2E, 2.8 WATER VALVE

VACUUM SWITCH VALVE.

Y18_LHD CONNECTOR DETAILS

PIN NUMBER FUNCTION

X1-1 12 V power

X1-2 Not Connected

X1-3 Water Valve

Figure 2F-112

TERMINALS RESISTANCE Ω

X1-1 and X1-3 93.5

4. VACUUM RETENTION TESTS

To operate efficiently, the HVAC system requires a constant vacuum source and all HVAC system vacuum

components must have no vacuum leaks. Vacuum is supplied by the engine induction system and is retained

within the HVAC system by the action of the one-way check valve located in the engine bay. A vacuum reserve is

stored within the vehicle cabin in the vacuum tank located on the left-hand side of the HVAC unit. Any of the

following components may cause o r co ntribute to a vacuum leak within the HVAC system:

• Check valve

• Vacuum tank

• Vacuum solenoid pack

• Water valve vacuum switch valve (LHD only)

• Vacuum actuators (including the water valve)

• Vacuum lines and manifold

Symptoms of a vacuum leak may be as follows:

• Constant coolant flow through the heater core

• Air always directed to the windscreen

• Air directed to ventilation outlets that are not selected

• Dust and/or smog ingress into the cabin despite the selection of the recirculation mode

• Constant ‘hissing’ noise emanating fro m a leaking or disconnected vacuum co mponent/s.

VACUUM LOSS DEFAULT SETTINGS

In the event of a vacuum loss, the OCC (Auto A/C) type HVAC unit will revert to a set of predetermined ‘safe to

drive’ default settings to allow continued operatio n of the vehicle until the fault is rectified.

Loss of vacuum supply to HVAC unit – LHD

If a total loss of vacuum occurs within the LHD type OCC (Auto A/C) system, the HVAC unit will default to the

following settings. The ventilation mode setting s will remain con stant regardless of what is displayed on the LCD

screen (1).

Regardless of recirculation switch (2) selection, the recirculation doors (3) will remain closed allowing outsi de air (4)

to enter and flow into the HVAC unit via the plenum chamber inlet (5). The position of the air mix doors (6) will

remain controllable as their function is el ectrically operated by the air mix motor. Heated coolant will flow through

the heater core (7), as vacuum is required to maintain the water valve in the cold (closed) po sition. The fa n switch

(8) will operate the blower fan (9) as normal. In any position of the mode switch (10), the face door (11) and the

floor door (12) will remain close d. The demist door (13) will be positioned so that all air (14) leaving the HVAC unit

will be directed to the demist outlets. Depending on the selected setting of temperature switch (15) and/or the

MIN MAX switch (16), this air may be cold, warm or hot air.

Figure 2F-113

Loss of vacuum supply to HVAC unit – RHD

If a total loss of vacuum occurs within the RHD type OCC (Auto A/C) system, the HVAC unit will default to the

following settings. The ventilation mode setting s will remain con stant regardless of what is displayed on the LCD

screen (1).

Regardless of recirculation switch (2) selection, the recirculation door (3) will remain closed allowing outside air (4)

to enter and flow into the HVAC unit via the plenum chamber inlet (5). The position of the air mix doors (6) will

remain controllable as their function is el ectrically operated by the air mix motor. Heated coolant will flow through

the heater core (7), as vacuum is required to maintain the water valve in the cold (closed) po sition. The fa n switch

(8) will operate the blower fan (9) as normal. In any position of the mode switch (10), the face door (11) will remain

closed. The demist/floor door (12) will be positioned so that all air (13) leaving the HVAC unit will be directed to the

demist outlets whether or not the demist switch (14) is selected. Depending on the selected setting of temperature

switch (15) and/or the MIN MAX switch (16), this air may be cold, warm or hot air.

Figure 2F-114

The following vacuum tests should be conducted to the HAVC system to isolate vacuum loss problems leading to

poor HVAC system performance. Perform each test in order until the problem is identified and corrected. The

vacuum retention tests in this Section apply only to OCC (Auto A/C) HVAC systems

NOTE: The vacuum components listed below are common to both Manual A/C and OCC (Auto A/C) HVAC

systems. For testing of the these components, refer to Section 2C, 8 VACUUM RETENTION TESTS.

• Check valve

• Vacuum tank

• Vacuum actuators (including the water valve)

4.1 VACUUM SOLENOID PACK

To vacuum test the solenoid pack perform the following:

1. Remove the vacuum solenoid pack. Refer to Section 2E, 2.7 VACUUM SOLENOID PACK.

2. Connect a vacuum pump (1) to the vacuum

supply port (2) of solenoid (3) and plug the

actuator port (4) below it.

3. Using the vacuum pump, create a vacuum and

observe the vacuum pump gauge needle.

4. If the needle remains steady it indicates that

the solenoid is retaining vacuum. If the vacuum

reading decreases, it indicates a vacuum leak

with that solenoid.

5. Repeat steps 1 to 3 for each solenoid of the

solenoid pack.

6. Install the vacuum solenoid pack. Refer to

Section 2E, 2.7 VACUUM SOLENOID PACK.

Figure 2F-115

4.2 VACUUM ACTUATOR LINES

LEFT- HAND DRIVE

To vacuum test the vacuum actuator lines an d on LHD type OCC (Auto A/C) HVAC units perform the following:

1. Remove the right-hand side instrument panel lower trim plate assembly.

Refer to Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Remove the plastic manifold from the vacuum solenoid pack. If required,

refer to Section 2E, 2.7. VACUUM SOLENOID PACK.

3. Using a vacuum pump, connect to the appropriate port of the plastic vacuum manifold. Refer to Figure 2F-116

and table below.

4. Using the vacuum pump, create a vacuum and observe the vacuum pump gauge needle. If the needle remains

steady it indicates that vacuum circuit is retaining vacuum. If the vacuum reading decreases, it indicates a

vacuum leak in that vacuum circuit.

5. If a vacuum leak is indicated check the vacuum tubing for damage or loose connection to the plastic manifold

and/or vacuum actuator. If there is no damage or loose connection, perform a vacuum test on the connecting

vacuum actuator.

6. Connect the plastic vacuum manifold to the vacuum solenoid pack ensuring that the vacuum manifold is fully

engaged to the two locking tangs of the solenoid pack.

7. Install the left-hand side instrument panel lower trim plate assembly.

Refer to Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

Figure 2F-116

Legend

1. Plastic Vacuum Manifold 4. Face 2 (Brown) 7. Vacuum Supply (White)

2. Foot 1 (Red) 5. Foot 1 (Blue) 8. Vacuum Pump

3. Defrost (Green) 6. Fresh / Recirculation (Yellow)

SOLENOID No. ACTUATOR VACUUM LINE COLOUR FUNCTION WHEN

VACUUM APPLIED

1 Foot Red Demist / Foot.

2 Demist Green Demist / Face

3 Face 2 Brown Bi-level

4 Face 1 Blue Face

5 Inlet Yellow Recirculation

RIGHT- HAND DRIVE

To vacuum test the vacuum actuator lines on RHD type OCC (Auto A/C) HVAC units perform the following:

1. Remove the left-hand side instrument panel lower trim plate assembly.

Refer to Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Remove the plastic manifold from the vacuum solenoid pack. If required, refer to

Section 2E, 2.7 VACUUM SOLENOID PACK.

3. Using a vacuum pump, connect to the appropriate port of the plastic vacuum manifold Refer to Figure 2F-117

and table below.

4. Using the vacuum pump, create a vacuum and observe the vacuum pump gauge needle. If the needle remains

steady it indicates that vacuum circuit is retaining vacuum. If the vacuum reading decreases, it indicates a

vacuum leak in that vacuum circuit.

5. If a vacuum leak is indicated check the vacuum tubing for damage or loose connection to the plastic manifold

and/or vacuum actuator. If there is no damage or loose connection, perform a vacuum test on the connecting

vacuum actuator.

6. Connect the plastic vacuum manifold to the vacuum solenoid pack ensuring that vacuum manifold is fully

engaged to the three locking tangs of the solenoid pack.

7. Install the left-hand side instrument panel lower trim plate assembly.

Refer to Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

Figure 2F-117

Legend

1. Plastic Vacuum Manifold 4. Foot 1 (Pink) 7. Fresh / Recirculation (Blue)

2. Water Valve (Yellow) 5. Face 2 (Green) 8. Vacuum Supply (Black)

3. Foot 2 (Orange) 6. Face 1 (White) 9. Vacuum Pump

SOLENOID No. ACTUATOR VACUUM LINE COLOUR FUNCTION WHEN

VACUUM APPLIED

1 Intake Blue Recirculation

2 Face 1 White Bi-level

3 Face 2 Green Face

4 Foot 1 Pink Blend

5 Foot 2 Orange Foot /Bi-level

6 Water valve Yellow Full cold

4.3 VACUUM MANIFOLD LINE

LEFT-HAND DRIVE

To vacuum test the vacuum manifold line on LHD type OCC (Auto A/C) HVAC units perform the following:

1. Remove the left-hand side lower trim plate assembly to access the vacuum tank, and right-hand side

instrument panel lower trim plate assembly to access the solenoid pack.

Refer to Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. To access the water valve vacuum switch valve, remove the radio assembly,

refer to Section 1A3, 3.6 RADIO ASSEMBLY. Remove also the radio housing and radio bracket assembly,

refer to Section 1A3, 3.11 RADIO HOUSING AND RADIO BRACKET ASSEMBLY.

3. Remove the plastic vacuum manifold (1) from the solenoid pack.

4. Remove the connector (2) of white vacuum manifold line (3) from the vacu um tank manifold line port (4).

5. Remove the connector (5) of white vacuum manifold line from the water valve vacuum switch valve (6).

6. Seal off the water valve vacuum switch valve connector with a suitable plug (7).

7. Connect a vacuum pump (8) to the vacuum manifold line connector. Seal the vacuum supply ports (9) on the

plastic vacuum manifold using a suitable strip of electrical tape (10).

8. Using the vacuum pump, create a vacuum and observe the vacuum pump gauge needle.

9. If a vacuum leak is indicated, check the condition of the vacuum line for damage or loose connection to the

plastic manifold and vacuum tank.

10. Replace components a s n ecessary.

If there is no fault or loose connection detected, perform a vacuum test on the water valve vacuum switch valve

and vacuum tank (if not already tested).

Figure 2F-118

RIGHT-HAND DRIVE

To vacuum test the vacuum manifold line on RHD type OCC (Auto A/C) HVAC units perform the following:

1. Remove the right-hand side instrument panel lower trim plate assembly,

refer to Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Remove the plastic vacuum manifold (1) from the solenoid pack.

3. Remove the connector (2) of vacuum manifold line (3) from the vacuum tank ma nifold line port (4).

4. Connect a vacuum pump (5) to the vacuum manifold line connector. Seal the vacuum supply ports (6) on the

plastic vacuum manifold using a suitable strip of electrical tape (7).

5. Using the vacuum pump, create a vacuum and observe the vacuum pump gauge needle.

6. If a vacuum leak is indicated, check the condition of the vacuum line for damage or loose connection to the

plastic manifold and vacuum tank.

7. Replace components a s n ecessary.

If there is no fault or loose connection detected, perform a vacuum test on the water valve and vacuum tank (if not

already tested).

Figure 2F-119

4.4 WATER VALVE VACUUM SWITCH

NOTE: The water valve vacuum switch valve is fitted to LHD type OCC (Auto A/C) HVAC units

1. Remove the radio assembly, refer to Section 1A3, 3.6 RADIO ASSEMBLY.

2. Remove the radio housing and radio bracket assembly,

refer to Section 1A3, 3.11 RADIO HOUSING AND RADIO BRACKET ASSEMBLY.

3. Locate the vacuum switch and valve (1) and

remove the vacuum hoses (2) noting their

installation to the valve.

4. Using a vacuum pump (3), connect to the

vacuum supply port (4) on the vacuum switch.

Vacuum seal the water valve vacuum port (5).

5. Using the vacuum pump, create a vacuum and

observe the vacuum pump gauge needle.

6. If a vacuum leak is indicated replace the water

valve vacuum switch valve.

Refer to Section 2E, 2.8 WATER VALVE

VACUUM SWITCH VALVE.

Figure 2F-120

5. WIRING DIAGRAMS

The following Figures provide electrical connector diagrams and wiring diagrams applicable to HVAC Occupant

Climate Control (Auto A/C) systems as fitted to MY2003 VY and V2 Serie s vehicles. These diagrams should be

used in conjunction with the diagn ostic chart circuit diagrams when diagnosing circuit faults. The content of these

figures is as follows:

• Electrical connectors – refer to Figure 2F-121

• Electrical connectors continued – refer to Figure 2F-122

• Electrical connectors continued – refer to Figure 2F-123

• V6 LHD wiring diagram – refer to Figure 2F-124

• V6 RHD wiring diagram – refer to Figure 2F-125

• GEN III V8 LHD wiring diagram – refer to Figure 2F-126

• GEN III V8 RHD wiring diagram – refer to Figure 2F-127

In the following wiring diagrams (Figure 2F-124 to Figure 2F-127) all compo nents are described and displayed in

accordance to the Integrated Vehicle Electrical Design (IVED) standard a s ap plied to MY2003 VY and V2 Series

vehicles. To assist in wiring diagram interpretation, refer to the following table:

IVED DESCRIPTION IVED COMPONENT IDENTIFICATION COMMON DESCRIPTION

Switch Asm – Ign & Start S149 Ignition Switch

V6 Module Asm Pwrt Cont A84 V6 Powertrain Control Module

V8 Module Asm Pwrt Cont A84 GEN III V8 Powertrain Control Module

Module Asm Body Cont A15 Body Control Module

Motor Asm Blo M3 Blower Motor

Module Asm Blo & Air Inl A13 Blower Motor Resistor

Module Asm Blo & A/C Cmpr A14_LHD OCC Control Module for LHD Models

Module Asm Blo & A/C Cmpr A14_RHD OCC Control Module for RHD Models

Actuator Asm Temp Vlv Y37 LHD Air Mix Motor for LHD Models

Actuator Asm Temp Vlv Y37 L Passenger’s Air Mix Motor for RHD Models

Actuator Asm Temp Vlv Y37 R Driver’s Air Mix Motor for RHD Models

Actuator Asm I/S Air Vlv Y19 Solenoid Pack

Actuator Asm Htr Wat Shutoff Vlv Y18_Lhd Water Valve VSV for LHD Models

Sensor Asm Amb Air Temp B23 Ambient Air Temperature Sensor

Sensor Asm I/S Air Temp B59 In-car Temperature Sensor

Sensor Asm Duct Air Temp B34 Evaporative Temperature Sensor

Coil A/c Clu L7 Compressor Clutch

Sensor Asm A/C Refrig Press B18 A/C Pressure Transducer

Motor Asm Eng Cool Fan M7_Std Standard Cooling Fan System

Motor Asm Eng Cool Fan M7_HP High Power Cooling Fan System

Window Rear R22 Heated Rear Window

The following table lists the IVED standard wire colour abbreviations:

BK Black D-GN Dark green L-GN Light green RD Red

BU Blue GN Green OG Orange TN Tan

BN Brown GY Grey PK Pink WH White

D-BU Dark blue L-BU Light blue PU Purple YE Yellow

NOTE 1: Electrical connectors specific to left-hand d rive or right-hand drive applications are identified in the

connector view diagram s b y a LHD or RHD notation after the connector description.

NOTE 2: For electrical connector locations and additional wiring di agram information

refer to Section 12P WIRING DIAGRAMS.

NOTE 3: V6 RHD domestic models are fitted with standard cooling fan system type fan motors. V6 RHD export

models may be fitted with high power cooling fan system ty pe fan motors. Where this applies, refer to the V6 RHD

wiring diagram Figure 2F-125, in conjunction with the cooling fan wiring details in the V6 LHD wiring diagram

Figure 2F-124.

NOTE 4: For visual identification of standard (STD) and high power (HP) cooling fan motors

refer to Section 2A, 2.9 COOLING FANS.

CONNECTORS: OCC SYSTEM

Figure 2F-121

CONNECTORS: OCC SYSTEM CONTINUED

Figure 2F-122

CONNECTORS: OCC SYSTEM CONTINUED

Figure 2F-123

WIRING DIAGRAM: OCC SYSTEM – V6 LHD

Figure 2F-124

WIRING DIAGRAM: OCC SYSTEM – V6 RHD

Figure 2F-125

WIRING DIAGRAM: OCC SYSTEM – GEN III V8 LHD

Figure 2F-126

WIRING DIAGRAM: OCC SYSTEM – GEN III V8 RHD

Figure 2F-127

6. SPECIAL TOOLS

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

7000086I

TECH 2

DIAGNOSTIC SCAN TOOL

Used for diagnosis of vehicle

electrical system.

Previously released.

Mandatory

J35616-A

(KM609)

CONNECTOR TEST ADAPTOR

KIT

Used when carrying out electrical

diagnostic circuit checks.

Previously released.

Desirable

3588

(J39200)

DIGITAL MULTIMETER

Must have at least 10 MΩ input

impedance and be capable of

reading frequenci es.

Previously released.

Available

J23738 VACUUM PUMP

Used for testing HVAC system

components, i.e. check valve,

HVAC unit vacuum tank, lines and

actuators.

Previously released.

Desirable