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Volvo 960 climate control & heater system repair manual

Volvo 960 service & repair manual

VOLVO 960 A/C-HEATER SYSTEM – AUTOMATIC

1994 Auto. A/C-Heater System Volvo 960

A/C SYSTEM SPECIFICATIONS

AUTOMATIC A/C SYSTEM SPECIFICATIONS TABLE

Application Specification

Compressor Type ……………….. Sanden SD-7H15 7-Cyl.

Or Seiko-Seiki SS-121DS5

Compressor Belt Deflection (1)

Refrigerant Capacity (R-134a) …………….. 32-34 ozs. Compressor Oil Capacity

Sanden SD-7H15 (2) ………………………. 8.5 ozs.

Seiko-Seiki SS-121DS5 (3) ………………… 7.8 ozs.

System Operating Pressures (4)

  1. – Belt tension is automatically adjusted by belt tensioner.

  2. – Use PAG Oil (Part No. 11 61 425-0).

  3. – Use PAG Oil (Part No. 11 61 426-0).

  4. – Information is not available from manufacturer.

    WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM procedures in appropriate

    AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY

    EQUIPMENT section.

    CAUTION: When battery or radio is disconnected, radio will go into anti-theft protection mode. Obtain radio code anti-theft protection code from owner prior to servicing vehicle.

    DESCRIPTION

    The Electronic Climate Control (ECC) system is an automatic A/C-heater system that monitors in-vehicle temperature through 2 sensors located in passenger compartment. One (solar) sensor is located on top of dashboard and senses sunlight. The second sensor is located in courtesy light fixture and senses temperature in center of vehicle.

    In addition to basic A/C-heater system components, system includes air intake temperature sensor, water (coolant) temperature sensor, servomotor and vacuum actuators. See Fig. 4.

    System is engaged when A/C button on control panel is pressed. See Fig. 1. Pressure switch on accumulator cycles compressor clutch on and off. Airflow modes are selected by center knob on control panel. Doors are controlled by vacuum motors on left side of heater case.

    volvo 960 ecc climate control airco ac controls buttons switches knobs dash

    Fig. 1: Automatic A/C-Heater System Control Panel Courtesy of Volvo Cars of North America

    OPERATION

    CONTROL PANEL

    The automatic A/C-heater system control panel permits manual operation of system by placing blower control knob or function selector knob in any position other than AUT (automatic). See Fig. 1.

    Blower fan may be automatically controlled by placing control knob in AUT position. Fan speed can also be manually controlled by placing control knob in any position except AUT or 0 (off) position.

    Function selector knob may be placed in defrost, vent, AUT, bi-level, or floor position. In AUT position, air distribution is automatically regulated. Air distribution may also be to floor, windshield and side windows.

    Temperature control knob may be used to select desired temperature. The recirculated air button may be pressed to recirculate passenger compartment air. This function, however, will not work in defrost position. Pressing A/C OFF button will turn automatic A/C system off.

    NOTE: Operational description of other components is not available from manufacturer. See Fig. 2.

    volvo 960 airco elements cooling fan condensor condenser drier sensor compressor

    Fig. 2: Identifying A/C-Heater System Components Courtesy of Volvo Cars of North America

    TROUBLE SHOOTING

    SELF-DIAGNOSTIC SYSTEM

    The EEC system incorporates a self-diagnostic function that indicates system faults through a series of trouble codes. The presence of fault(s) is indicated by flashing A/C OFF button. The control panel is programmed to enter a pre-programmed mode when a fault is detected. Under fault condition, control panel ignores the faulty signal, selects an alternative pre-programmed value and prevents delivery of faulty output signals.

    Entering Self-Diagnostics

    1. To enter mode, ensure engine is running. Shine a non-

      fluorescent, bright light on solar sensor. Place blower fan control knob in AUT position and function selector knob in vent position.

    2. Place temperature control knob to maximum cooling (pointing straight down). Ensure recirculated air switch is depressed and A/C OFF button is released. Depress and release A/C OFF button within 5 seconds to start self-diagnostic mode.

    3. Each fault code consists of 3 digits. For example, Code

      132 is displayed by a single flash of the A/C OFF button for the first digit (number 1). After a pause, the second digit of code (number 3) is indicated by 3 flashes. After another pause, the third digit of code (number 2) is indicated by 2 flashes. See TROUBLE CODE IDENTIFICATION table.

    4. Three different fault codes may be stored in memory. However, only one code may be displayed upon request. It may be necessary to request display of fault codes a number of times to ensure all fault codes are displayed.

Exiting Self-Diagnostics & Clearing Codes

To exit self-diagnostics, turn ignition off. All codes are cleared when ignition is turned off. Fault codes are not stored in memory. Even if a code has occurred several times during a period of time, code will only be stored until ignition is turned off.

TROUBLE CODE IDENTIFICATION TABLE

Affected Circuit/Sensor Code

Fault Free System 111

Outside Temperature Sensor

Short Circuit To Ground 121

Open Circuit Or Short Circuit To 12 Volts 122

In-Vehicle Temperature Sensor

Short Circuit To Ground 131

Open Circuit Or Short Circuit To 12 Volts 132

Water (Coolant) Temperature Sensor

Short Circuit To Ground 141

Open Circuit Or Short Circuit To 12 Volts 142

Alternator (D+ Signal Fault) 151

Solar Sensor 161

Servomotor/Potentiometer

Open Circuit Or Short Circuit To Ground 211

Short Circuit To 12 Volts 212

Servomotor

Incorrect 12-Volt Supply To Pins No. 17 & 18 213

Servomotor

Fails To Operate Within 10 Seconds 214

ECC Control Panel

Faulty Temperature Control 231

Fan Motor Excessive Starting Current 233

Power Unit – Incorrect 12-Volt Supply Affected Output:

Coolant Valve 241

Bi-Level 242

Vent 243

Recirculated Air 244

Defrost 245

Floor 246

Fan (Maximum Speed Relay) 247

A/C Compressor 248

Radiator Fan Relay 249

TESTING

VACUUM CIRCUITS

Using vacuum schematic and vacuum functions table, test for proper operation of vacuum circuits. See Fig. 3.

volvo 960 vacuum system ecc airco airconditioning ac a/c

Fig. 3: Testing Vacuum Circuits Courtesy of Volvo Cars of North America

REMOVAL & INSTALLATION

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM procedures in appropriate

AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY

EQUIPMENT section.

BLOWER MOTOR

Removal & Installation

  1. Obtain radio anti-theft code before servicing vehicle. Disconnect negative battery cable. Remove trim panel below glove box. Open glove box door. Remove glove box screws and glove box.

  2. Detach wiring harness and bracket from blower motor housing. Disconnect blower motor. Remove blower motor screws and blower motor. To install, reverse removal procedure.

EVAPORATOR CORE

Removal & Installation

  1. Obtain radio anti-theft code before servicing vehicle. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove receiver-drier from engine compartment firewall. Remove cover plate and foam rubber seal from firewall.

  2. Remove trim panel below glove box. Open glove box door. Remove glove box screws and glove box. Remove evaporator housing end cover. See Fig. 4. Carefully remove evaporator core. To install, reverse removal procedure.

NOTE: Additional removal and installation procedures are not available from manufacturer.

volvo 960 airco removal installation parts airco ac airconditiong air conditioning heater system

Fig. 4: Exploded View Of Evaporator/Blower Motor Housing Courtesy of Volvo Cars of North America

WIRING DIAGRAM

volvo 960 climate control automatic airco airconditioning ac wiring diagram

Fig. 5: Automatic A/C-Heater System Wiring Diagram

 

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