A/C Reduced Heater Output At An Idle
TSB 10-4-403/15/10
3.5L REDUCED HEATER DUCT DISCHARGE
TEMPERATURE AT IDLE - BUILT ON OR BEFORE
1/19/2009
FORD:
2009 Flex
This article supersedes TSB 10-2-11 to update the Service Procedure and Service Labor Time Standards.
ISSUE
Some 2009 Flex vehicles built on or before 1/19/2009 may exhibit a customer concern of reduced heater duct discharge temperature when the vehicle engine is brought down to an idle speed.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF A VEHICLE HAS A BUILD DATE OF 1/19/2009 AND WAS PRODUCED WITH MOTORCRAFT(R) SPECIALTY GREEN ENGINE COOLANT, VC-10-A2 (US); CVC-10-A (CANADA), THIS PROCEDURE DOES NOT APPLY. REFER TO NORMAL WORKSHOP MANUAL (WSM) DIAGNOSTICS, SECTION 412-00.
Heater Performance Verification Test
1. Drive vehicle for a minimum of 20 minutes.
2. Ensure that the thermostat is open by checking for heat at the upper radiator hose. If the thermostat is not open, continue to drive.
3. Set the front climate temperature control to 90 °F (32 °C) and turn off the auxiliary climate control.
4. Set the mode to panel/vent and A/C switched off. Do not set to recirculation mode.
5. Set the blower to highest speed and open all panel vents.
6. Idle the engine for additional 20 minutes at an ambient of 60 °F (15.5 °C) or above with the hood down.
7. The left center vent discharge air temperature should be a minimum of 137 °F (58 °C) at 60 °F (16 °C) ambient.
a. If the heater performance meets the minimum 137 °F (58 °C) criteria, stop with this procedure and proceed to WSM, Section 412: Climate Control System Diagnostics and Testing.
b. If the heater performance does not meet the minimum 137 °F (58 °C) criteria, then proceed to Cooling System Flush.
Flushing Equipment Fabrication
1. Prior to starting the service flush procedure, prepare the fresh water supply hose and the drain hose. Obtain two (2) hose coupling adapters, six (6) number 12 hose clamps and one (1) garden hose (obtain locally). The garden hose can be either a 5/8" (16 mm) or 3/4" (19 mm). The couplings can be 5/8" (16 mm) x 3/4" (19 mm) or 3/4" (19 mm) x 3/4" (19 mm) depending on the size garden hose used. The vehicle hose and thermostat port are 3/4" (19 mm) in size. (Figure 1)
2. Using a coupling adapter and hose clamps, cut the garden hose to length (one end of the hose must reach from the vehicle to a fresh water supply faucet and the drain hose end should be long enough to drain the engine coolant away from the vehicle) and attach a 2' (61 cm) length of heater hose to the garden hose to be used as the fresh water supply. The heater hose will prevent kinking at the tight area of the engine compartment. (Figure 2)
3. Using a coupling adapter and hose clamps, attach a 2' (61 cm) length of heater hose to the remaining section of garden hose to be used as the drain hose. The heater hose will prevent kinking at the tight area of the engine compartment. (Figure 3)
Cooling System Flush
NOTE
DISPOSE OF OLD COOLANT AND FLUSHING WATER CONTAMINATED WITH ANTIFREEZE AND CLEANING CHEMICALS IN ACCORDANCE WITH LOCAL, STATE OR FEDERAL LAWS.
1. Drain the cooling system. Refer to WSM, Section 303-03. Leave the draincock open and splash shield off.
2. Remove the air cleaner assembly. Refer to WSM, Section 303-12.
3. Disconnect the heater core outlet hose (Item 4) and the heater core inlet hose (Item 5) from the thermostat housing and position them aside. (Figure 4)
4. Install pinch-off pliers to the rear heater core inlet hose (Item 5, Figure 4) just below the inlet tee fitting. Do not remove pinch-off pliers until after the rear heater core has been flushed.
5. Connect the fresh water supply hose to the heater outlet hose. (Item 4, Figure 4)
6. Attach a drain hose to the heater inlet hose (Item 5, Figure 4) to prevent coolant from splashing and staining the engine compartment.
7. Back flush the front heater core through the heater outlet with approximately four (4) gallons (15 L) of tap water until water is clear.
8. Disconnect the rear heater core inlet hose at the rear of the vehicle. (Figure 5)
9. Install pinch-off pliers to the drain hose. (Item 5, Figure 4)
10. Position drain pan underneath rear heater core.
11. Turn on the water supply and back flush front and rear heater cores with tap water until approximately two (2) gallons (7.6 L) have filled the drain pan.
12. Remove pinch-off pliers from rear heater core inlet hose (Item 5, Figure 4) and install on the rear heater core outlet hose (Item 4, Figure 4) just below the outlet tee fitting.
13. Back flush the underbody metal heater inlet line with tap water until water is clear.
14. Connect the rear heater core inlet hose.
15. Remove pinch-off pliers from drain hose and pinch off rear heater core inlet hose (Item 5, Figure 4). Leave heater core outlet hose (Item 4, Figure 4) pinched off.
16. Disconnect the drain hose and reconnect heater core inlet hose to thermostat housing.
17. Connect the garden drain hose to the heater core outlet hose (Item 4, Figure 4). This will be used to allow the engine to drain away from the engine compartment.
18. Connect the fresh water supply hose to the heater return port (Item 10, Figure 4) on the thermostat housing.
19. Install the air cleaner assembly. It is not necessary to install the bolts; air cleaner will be removed again. It is important to install the air cleaner assembly to prevent stalling the engine. Make sure that the two air cleaner feet are seated into the rubber grommets under the air cleaner assembly. The air cleaner outlet pipe should be securely sealed to prevent unmetered air from entering the engine.
CAUTION
THE UPPER RADIATOR HOSE MUST BE PROPERLY POSITIONED BELOW THE LOCATING BRACKET ON THE COOLING FAN SHROUD AS SHOWN. FAILURE TO PROPERLY POSITION THE HOSE COULD RESULT IN ENGINE OVERHEATING. (FIGURE 6)
20. Install and configure the Integrated Diagnostic System (IDS) scan tool to monitor and activate the engine RPM number and High Speed Cooling Fan FAN_CTRL.
a. Enter the vehicle information and then select the datalogger tab and the check tick icon from the toolbox menu.
b. Select powertrain from data logger menu then select engine, check tick icon.
c. Select the eraser Icon and then the check tick icon to clear all selections.
d. Select to highlight both the FAN_CTRL number and the RPM number buttons.
e. Select the check tick icon to display the FAN_CTRL number and the RPM number pids.
21. Turn on the fresh water supply. Allow the degas bottle to fill to the max cold fill range then tighten the cap to prevent over[lowing (radiator drain valve should still be open).
22. Start the engine.
23. Using active command on the IDS, set the engine RPM to 2000 RPM.
a. Highlight the RPM display, and then select the number icon.
b. Select the button icon below the number icon to activate control of RPM.
c. Press the plus icon below the button icon to increase the RPM speed.
NOTE
IT IS IMPORTANT TO EXIT IDS ACTIVE COMMAND BY USING THE ERASER BUTTON ON THE IDS TO PREVENT ENGINE STALLING.
24. Run the engine for two (2) minutes (radiator drain valve should still be open, pressure cap installed, and coolant draining from the heater core outlet drain hose). It may be necessary to adjust the fresh water supply flow rate and crack the degas bottle cap periodically to ensure the system remains full of fluid throughout the procedure.
25. Return the engine to normal idle by selecting the eraser button on the IDS.
26. Stop the engine and turn off the fresh water supply.
27. Slowly remove the degas bottle cap.
28. Allow system to drain through the radiator drain valve.
29. Remove the air cleaner assembly.
30. Remove pinch-off pliers from both rear heater core hoses.
31. Disconnect the flush hoses from the heater return port and heater core outlet hose. (Item 4, Figure 4)
32. Reconnect the heater core outlet hose (Item 4, Figure 4) to the thermostat return port.
33. Install air cleaner assembly. It is not necessary to install the bolts; air cleaner will be removed again.
34. Once the radiator is completely drained, close the radiator drain valve. The Heating Ventilation Air Conditioning (HVAC) blower motor must be turned off to make sure the thermostat opens. The high speed fan active command must be off to make sure the thermostat opens.
35. Add one (1) 22 fluid oz. bottle of Motorcraft(R) Premium Cooling System Flush to the degas bottle. (Do not use Ford Neutral pH Iron Cleaner, F8AZ-19A503-AA, or Motorcraft(R) Engine Cooling System Iron Cleaner, VC-9, as these products are for rust removal).
36. Add fresh water to the degas bottle until the water reaches the maximum cold fill range. Follow WSM, Section 303-03 filling procedures.
37. Start the engine and let idle with the degas cap off for two (2) minutes to allow trapped air in the engine to escape.
38. Stop the engine and wait for one (1) minute to make sure air is purged from the radiator.
39. Add additional water to the bottle if required to bring the volume up to the maximum cold fill level.
40. Bleed air from the cooling system using the following procedure.
a. Close the degas bottle cap.
b. Start the engine and let idle until the engine reaches normal operating temperature and the thermostat is fully open. A fully open thermostat can be verified by the radiator fan cycling on at least once.
c. Turn the engine off for one (1) minute.
d. Run the engine at a minimum of 3500 RPM for thirty (30) seconds.
e. Run the engine at idle for thirty (30) seconds.
f. Repeat steps c-e for a total of ten (10) times.
CAUTION
THE FLUSHING SOLUTION CONTAINS NO GLYCOL, THE SYSTEM WILL BOIL BEFORE THE FANS TURN ON IF THE PRESSURE CAP IS NOT FITTED CORRECTLY.
41. Remove the air cleaner assembly.
42. Install pinch-off pliers on rear heater inlet (Item 5, Figure 4) and rear heater outlet hoses. (Item 4, Figure 4)
43. Install air cleaner assembly. It is not necessary to install the bolts; air cleaner will be removed again.
44. Start the engine.
45. Using active command with IDS set the engine RPM to 2000 RPM.
46. Run the engine for five (5) minutes at 2000 RPM to allow the thermostat to open.
WARNING
IF THE ENGINE OVERHEATS OR THE FLUID LEVEL DROPS BELOW THE MINIMUM FILL LINE, SHUTOFF THE ENGINE AND ADD FLUID TO THE DEGAS BOTTLE MAXIMUM FILL LINE ONCE THE ENGINE COOLS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE ENGINE. ALWAYS ALLOW THE ENGINE TO COOL BEFORE OPENING THE COOLING SYSTEM. DO NOT UNSCREW THE COOLANT PRESSURE RELIEF CAP WHEN THE ENGINE IS OPERATING OR THE COOLING SYSTEM IS HOT. THE COOLING SYSTEM IS UNDER PRESSURE; STEAM AND HOT LIQUID CAN COME OUT FORCEFULLY WHEN THE CAP IS LOOSENED SLIGHTLY.
47. Return the engine to normal idle by using the eraser button on the IDS.
48. Stop the engine.
49. Remove the air cleaner assembly.
50. Remove pinch-off pliers from both rear heater core hoses.
51. Install air cleaner assembly. It is not necessary to install the bolts; air cleaner will be removed again.
52. Key On engine Off.
53. Using active command with IDS turn on the high speed cooling fan.
a. With the ignition key on and the engine off highlight the FAN_CTRL number display.
b. Enter IDS active command by selecting the number icon.
c. Select the button icon below the number icon to activate control of the cooling fan.
d. Press the plus icon below the button icon to turn on the cooling fan.
54. Wait five (5) minutes with high speed fan running before continuing to next step.
55. Turn off the high speed fan by selecting the eraser button on the IDS. Turn off the ignition key.
56. Slowly remove the degas bottle cap and top off the degas bottle with tap water.
57. Start the engine and let Idle with the degas cap off for two (2) minutes to allow trapped air in the engine to escape.
58. Stop the engine and wait for one (1) minute to make sure air is purged from the radiator.
59. Add additional water to the bottle if required to bring the volume up to the maximum cold fill level.
60. Install the degas bottle pressure cap.
61. Start the engine.
62. Using active command with IDS, set the engine RPM to 2000 RPM.
63. Run the engine for ten (10) minutes at 2000 RPM to allow the thermostat to open.
WARNING
IF THE ENGINE OVERHEATS OR THE FLUID LEVEL DROPS BELOW THE MINIMUM FILL LINE, SHUT OFF THE ENGINE AND ADD FLUID TO THE DEGAS BOTTLE MAXIMUM FILL LINE ONCE THE ENGINE COOLS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE ENGINE. ALWAYS ALLOW THE ENGINE TO COOL BEFORE OPENING THE COOLING SYSTEM. DO NOT UNSCREW THE COOLANT PRESSURE RELIEF CAP WHEN THE ENGINE IS OPERATING OR THE COOLING SYSTEM IS HOT. THE COOLING SYSTEM IS UNDER PRESSURE; STEAM AND HOT LIQUID CAN COME OUT FORCEFULLY WHEN THE CAP IS LOOSENED SLIGHTLY.
64. Return the engine to normal idle by using the eraser button on the IDS.
65. Stop the engine.
66. Key On engine Off.
67. Using active command with IDS, turn on the high speed cooling fan.
a. With the ignition Key on and the engine off, highlight the FAN_CTRL number display.
b. Enter IDS active command by selecting the number icon.
c. Select the button icon below the number icon to activate control of the cooling fan.
d. Press the plus icon below the button icon to turn on the cooling fan.
68. Wait five (5) minutes with high speed fan running before continuing to next step.
69. Turn off the high speed fan by selecting the eraser button on the IDS. Turn off the ignition key.
70. Slowly remove the degas bottle cap and rinse with fresh water to clean the Motorcraft(R) Premium Cooling System Flush off of the cap.
71. Open the radiator drain valve and allow the system to completely drain.
72. Remove the air cleaner assembly to gain access to thermostat housing and disconnect the heater core outlet hose. (Item 4, Figure 4)
73. Attach the drain hose to the heater core outlet hose (Item 4, Figure 4) and the fresh water supply hose to the heater return port on the thermostat housing.
74. Install air cleaner assembly. It is not necessary to install the bolts; air cleaner will be removed again.
75. Turn on the fresh water supply. Allow the degas bottle to fill to the maximum cold fill range then install the degas bottle cap. Tighten the cap to prevent over[lowing (radiator drain valve should still be open).
76. Start the engine and let idle for two (2) minutes to allow trapped air in the engine to escape.
77. Stop the engine and wait for one (1) minute to make sure air is purged from the radiator.
78. Add additional water to the bottle if required to bring the volume up to the maximum cold fill level.
79. Install the degas bottle pressure cap.
80. Using active command with IDS set the engine RPM to 2000 RPM.
81. Run the engine for five (5) minutes at 2000 RPM. (radiator drain valve should still be open, pressure cap installed, and coolant draining from the heater core outlet drain hose). It may be necessary to adjust the fresh water supply flow rate and crack the degas bottle cap periodically to ensure the system remains full of fluid throughout the procedure.
82. Stop the engine and turn off the fresh water supply.
83. Slowly remove the degas bottle cap.
84. Allow system to drain through the radiator drain valve.
85. Remove the air cleaner assembly.
86. Disconnect flush hoses from the heater return port and heater core outlet hose. (Item 4, Figure 4)
87. Connect the heater core outlet hose (Item 4, Figure 4) to the thermostat return port.
88. Install the air cleaner assembly. Refer to WSM Section 303-12.
89. Run fresh water through the degas bottle to remove residual Motorcraft(R) Premium Cooling System Flush.
90. Once the radiator is completely drained, close the radiator drain valve and install the splash shield. The engine at this stage is filled with pure water. The engine holds approximately 50% of the cooling system capacity.
91. Add 5.8 qts. (5.5 L) for base models and 6.3 qts. (6.0L) for trailer tow models (has oil cooler) of 100% pure concentrate coolant, Motorcraft(R) Premium Gold Engine Coolant with Bittering Agent, to the cooling system.
92. Top off the degas bottle to 1" (25 mm) above the top of the cold fill range with fresh water.
93. Bleed air from the cooling system using the following procedure.
a. Close the degas bottle cap.
b. Turn the HVAC system to off.
c. Start the engine and let idle until the engine reaches normal operating temperature and the thermostat is fully open. A fully open thermostat can be verified by the radiator fan cycling on at least once.
d. Turn the engine off for one (1) minute.
e. Run the engine at a minimum of 3500 RPM for 30 seconds.
f. Run the engine at idle for thirty (30) seconds. If the engine overheats or the fluid level drops below the top of the cold fill range, shut off the engine and add fluid to 1" (25 mm) above the top of the cold fill range once the engine cools.
g. Repeat steps d-f for a total of ten (10) times.
WARNING
ALWAYS ALLOW THE ENGINE TO COOL BEFORE OPENING THE COOLING SYSTEM. DO NOT UNSCREW THE COOLANT PRESSURE RELIEF CAP WHEN THE ENGINE IS OPERATING OR THE COOLING SYSTEM IS HOT. THE COOLING SYSTEM IS UNDER PRESSURE; STEAM AND HOT LIQUID CAN COME OUT FORCEFULLY WHEN THE CAP IS LOOSENED SLIGHTLY.
h. Check the engine coolant level in the degas bottle and fill to 1" (25 mm) above the top of the cold fill range when warm or to the top of the cold fill range line when cold.
i. Install the degas bottle cap to at least one audible click.
94. Perform Heater Performance Verification Test.
a. If heater performance is restored to the minimum 137 °F (58 °C) criteria return the vehicle to the customer.
b. If heater performance is not restored to the minimum 137 °F (58 °C) after the cooling system flush, replace the front heater core. Refer to WSM, Section 412-01 for removal and installation.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
100404A 2009 Flex: Flush The 4.9 Hrs.
Cooling System Following
The Service Procedure,
System Passes Heater
Performance Verification
Test Return To Customer
(Do Not Use With Any
Other Labor Operations)
100404B 2009 Flex: Flush The 10.5
Cooling System Following Hrs.
The Service Procedure,
System Fails Heater
Performance Verification
Test, Replace The Front
Heater Core (Do Not Use
With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
8A080 55
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