Electrical Interference In ECC Control Module - Kit (GROUP 87, NO. 817)

FAULT TYPE 1

ECC system stuck in the max. position for either hot or cold or has some other extreme fault.

Cause: External electrical interference can have affected the program.

Analysis method: Interference continues until the ignition is turned off. When the ignition is again activated the program resets and performs normally.

If DTCs 321, 322, 323, or 324 are posted and no fault can be detected, the control system can be malfunctioning due to interference.

Repairs: By applying a 5 V current to pins 3 and 4 in the control module 10-pin connector according to the method described in this Service Bulletin, the control module will not be affected by external electronic interference.

Carry out operations in SERVICE PROCEDURES section.

FAULT TYPE 2

The blower motor suddenly stops or does not start.

Cause A: The control program is not affected by external electrical interference but the blower motor is using too much power. There is an integral overload protection in the power stage which breaks the circuit to the blower motor if the power consumption exceeds 35 amps.

The overload device resets when the ignition is switched off.

Analysis method: The blower motor consumption must not exceed 27 amps at constant speed on the max. speed.

Repairs: Refer to Service Manual at CR.

Refer to SERVICE PROCEDURES section of this bulletin.

Cause B: The power stage overload breaks the circuit when the supply is too low.

Analysis method: Refer to Service Manual at CX.

Repairs: Perform operations at CX according to Service Manual.

Then carry out operations in SERVICE PROCEDURES section of this bulletin.

FAULT TYPE 3

The in-car temp. sensors registered the wrong temperature.

Cause: The grilles in the headliner are not in the correct position in relation to the sensors.

Can only occur on 854 cars with chassis numbers up to and including 046285 fitted with the older sensor type.

Analysis method: Check the position of the grilles in the headliner in relation to the sensors so that they are directly in front of the center of the sensors and that the headliner is up against the foam seal on the sensors.

*  Press in the foam seal round the entire sensor to ensure a complete and good seal. (Refer to Service Manual at section SB. )

Repairs: If one or both grilles are incorrectly positioned or if the sealing is not complete, then the sensors and grilles should be replaced with the latest versions to ensure correct in-car temperature registration.

Then carry out operations in the SERVICE PROCEDURES section.

FAULT TYPE 4

Incorrect setting on controls

Cause A: Closed dash vents and Air-mix open.

Analysis method: Check if the control setting is correct. Owner/driver can have set the controls incorrectly.

Repairs: Inform customer that driving with closed dash vents and open Air-mix results in incorrect air-flow in the ECC climate unit with resulting control function error. This is similar to that obtained from electrical interference.

Remark: If the Air-mix is open, the center dash vents must always be fully open.

Then carry out operations in the SERVICE PROCEDURES section.

Cause B: Completely closed outer dash vents result in the ECC unit reacting slowly.

Analysis method: Check if the control setting is correct.

Repairs: The dash vents should never be completely closed. Open them slightly.

Then carry out operations in the SERVICE PROCEDURES section.

INSTALL CABLE HARNESS

• Remove glove compartment insert according to Service Manual point G, Blower motor, replacement. * Detach connector from shutter motor for the floor/defroster shutter.

The shutter motor is in back of the glove compartment, as shown in Fig 2 .

Fig 2: Location of Shutter Motor

* Connect the connector on the cable harness to the disconnected connector and to the shutter motor.

* Install foam supplied with cable harness around the cable harness connector to prevent rattling.

*  Remove control module and detach connector 4/30C according to Service Manual - operation BD, Connection and disconnection of test box.

Let the two long cables go along the existing cable harness to the control module. Use cable ties to clamp the cable harnesses together.

* Open the secondary locking on the connector 4/30C.

* Attach cables to terminals 3 and 4 in the 10-pin connector 4/30C.

See Fig 3 .

* Close the secondary locking.

* Connect connector to the control module.

* Install the control module.

* Test functions.

* Replace all parts removed.

Fig 3: Attaching Cables to Connector 4/30C

SETTING END POSITION (CONTROL CODE 9-9-9)

Set the shutter motor end position when car has chassis number prior to: 854-149800 and 855-054500.

SETTINGS BEFORE ACTIVATION

(See Fig 4 )

* Blower switch in MANUAL position, approx. half effect.

* Recirculation ON.

* Left temperature control set to MAX cooling, blue markings.

* Right temperature control set to MAX heating, red markings.

* Air flow selector set to point between Ventilation/Defrost.

* A/C switch can be in the ON/AUTO or OFF position (has no effect on calibration).

Fig 4: Climate Control Panel

ACTIVATE FUNCTION TEST 4

Self-adjusting of shutter motor end position.

* Ignition on.

* Press four times on the button (hold down approx. 1 sec. for each press).

The LED lights when Function test 4 is activated.

Fig 5: Location of Button

If LED does not indicate when button pressed:

*  Continue with checking DTC BC according to the Service Manual.

The control module can accept a command code when the LED is blinking.

* Enter command code 9-9-9 according to Service Manual, Entering codes BA5.

* Press a series of nine short pushes on the button. Enter the series three times with a short pause after each series of nines, so the LED has time to indicate again.

The control module is now activated to carry out self-adjustment of the shutter motor end positions.

* Wait approx. 10 seconds so the blower motor has time to start. See Fig 6 .

* Ignition off, to exit Function test 4.

* Ignition on.

Fig 6: Exiting Function Test 4

A/C and REC indicator LEDs on the control module are blinking.

* Continue to test driving the car section.

CHECKING IF THE CONTROL MODULE IS ACTIVATED FOR SELF-ADJUSTMENT

* Start Function test 1 to read off posted DTCs for faults traced by the control module's on-board diagnostic system (OBDS). See Fig 7 .

* Ignition on.

* Press button. Hold down approx. 1 second.

* Read off the LED flashes.

Fig 7: Activating Function Test 1

If LED does not indicate when button pressed:

* Check the Diagnostic socket.

Check if the control module is activated for self-adjustment.

*  Start the Function test 1 BA3 according to the Service Manual.

* Read off the DTC.

Diagnostic trouble code 5-1-1 posted: 

The control module is activated for self-adjustment of the shutter motor end position.

* Continue with testing the car in the test drive section.

If DTC 5-1-1 is not posted: 

Start of Function test 4 and entering command code 9-9-9 has failed.

* carry out settings before activation.

TEST DRIVING THE CAR

* drive car a few minutes at a speed over 30 Km/h (18 mi/h). The control module will carry out the self-adjustment while the car is being driven. See Fig 8 .

* Stop the car and leave ignition on for at least 2 minutes so the control module can store all the values.

* Continue to Checking self-adjustment.

Fig 8: Test Driving the Car

CHECKING SELF-ADJUSTMENT IS NOW COMPLETE

* Ignition on.

*  Start the Function test 1 BA3 according to the Service Manual.

* Read of the DTC.

Diagnostic trouble code 1-1-1 posted: 

No fault recorded. Self-adjustment complete.

Diagnostic trouble code 5-1-1 posted: 

Self-adjustment is not complete.

* Carry out Settings before activation.

* Then carry out activating Function test 4 and follow with checking if control modules activated for self-adjustment.