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2012 Focus
412-00 Climate Control - EMTC DESCRIPTION AND OPERATION

Climate Control - EMTC

Component Location

Item Description

1 Air inlet duct

2 Blower motor

3 Evaporator core

4 Heater core

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Item Description

1 Actuating assembly

2 Defrost/panel/floor airflow mode door actuator

3 Blower motor speed control

4 Temperature blend door actuator

5 Evaporator discharge air temperature sensor

6 Air inlet door mode door actuator

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Item Description

1 A/C compressor

2 Compressor-side compressor-to-condenser discharge line

3 Condenser-side compressor-to-condenser discharge line

4 Condenser core

5 TXV manifold and tube assembly

6 TXV

7 Evaporator core

8 Evaporator-to-compressor suction line

9 A/C pressure transducer

10 Integrated receiver/drier (part of condenser core)

Overview

WARNING: Take the following precautions when repairing an air conditioning system containing R-
134a:

Always wear safety goggles.

Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25 C (-13 F) under
atmospheric pressure and will freeze skin tissue.

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Never allow refrigerant R-134a gas to escape in quantity in an occupied space. It will displace the
oxygen needed to support life.

Never use a torch in an atmosphere containing R-134a gas. R-134a is non-toxic at all normal
conditions, but it decomposes when exposed to high temperatures such as a torch flame. During
decomposition it releases irritating and toxic gasses (as described in the MSDS sheet from the
manufacturer). Decomposition products are hydrofluoric acid, carbon dioxide and water.
Failure to follow these instructions may result in serious personal injury.
NOTICE: To avoid damaging the vehicle or A/C components, the following precautions must be observed.

The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging.
Failure to do so can contaminate the shop bulk refrigerant and other vehicles.

Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These 2
types of refrigerant must never be mixed. Doing so can damage the A/C system.

Charge the A/C system with R-134a refrigerant gas while the engine is running only at the low-
pressure side to prevent refrigerant slugging from damaging the A/C compressor.

Use only R-134a refrigerant. Due to environmental concerns, when the A/C system is drained, the
refrigerant must be collected using refrigerant recovery/recycling equipment. Federal,
State/Provincial and/or local laws REQUIRE that R-134a be recovered into appropriate recovery
equipment and the process be conducted by qualified technicians who have been certified by an
approved organization, such as ASE or MACS. Use of a recovery machine dedicated to R-134a is
necessary to reduce the possibility of oil and refrigerant incompatibility concerns. Refer to the
instructions provided by the equipment manufacturer when removing refrigerant from or charging
the A/C system.

Refrigerant R-134a must not be mixed with air for leak testing or used with air for any other purpose
above atmospheric pressure. R-134a is combustible when mixed with high concentrations of air and
higher pressures.

A number of manufacturers are producing refrigerant products that are described as direct
substitutes for refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely
damage the A/C components. If repair is required, use only new or recycled refrigerant R-134a.
NOTICE: To avoid contamination of the A/C system, the following precautions must be observed.

Never open or loosen a connection before recovering the refrigerant.

When loosening a connection, if any residual pressure is evident, allow it to leak out before opening
the fitting.

Evacuate a system that has been opened to install a new component or one that has discharged
through leakage before charging.

Seal open fittings with a cap or plug immediately after disconnecting a component from the system.

Clean the outside of the fittings thoroughly before disconnecting a component from the system.

Do not remove the sealing caps from a new component until ready to install.

Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil
container until ready to use and install the cap immediately after using. Store the oil in a clean,
moisture-free container.

Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal with PAG
oil before connecting.

When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or any
sharp edges that can chafe the line.

Tighten threaded fittings only to specifications. The steel and aluminum fittings used in the
refrigerant system will not tolerate overtightening.

When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the
refrigerant lines or tubes.

Do not open a refrigerant system or uncap a new component unless it is as close as possible to room

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temperature. This will prevent condensation from forming inside a component that is cooler than the
surrounding air.
The EMTC system heats or cools the vehicle depending on the HVAC control panel selection.

The control panel selection determines heating or cooling, air distribution and enables blower motor
operation.

The temperature control setting determines the outlet air temperature.

The blower motor switch varies the blower motor speed.

During A/C operation, the system reduces the relative humidity of the air inside the vehicle.

System Operation

System Diagram

EMTC

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The Refrigerant Cycle

During stabilized conditions ( A/C system shutdown), the refrigerant pressures are equal throughout the system.

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When the A/C compressor is in operation, it uses a piston pump to compress the cool vapor, causing it to become
high-temperature/high-pressure vapor. The high-temperature/high-pressure vapor is then released into the top of
the A/C condenser core.
The A/C condenser, being close to ambient temperature, causes the refrigerant vapor to condense into a liquid
when heat is removed from the refrigerant by ambient air passing over the fins and tubing. The now liquid
refrigerant, still at high pressure, exits from the bottom of the A/C condenser and enters the inlet side of the A/C
receiver/drier (integral to the condenser). The receiver/drier is designed to remove moisture and contaminants
from the refrigerant system.
The outlet of the receiver/drier is connected to the TXV. The TXV provides the orifice, which is the restriction in
the refrigerant system, and separates the high and low pressure sides of the A/C system. As the liquid refrigerant
passes across this restriction, its pressure and boiling point are reduced.
The liquid refrigerant is now at its lowest pressure and temperature. As it passes through the A/C evaporator, it
absorbs heat from the airflow passing over the plate/fin sections of the A/C evaporator. This addition of heat
causes the refrigerant to boil (convert to gas). The now cooler air can no longer support the same humidity level
of the warmer air and this excess moisture condenses on the exterior of the evaporator coils and fins and drains
outside the vehicle.
The refrigerant cycle is now repeated with the A/C compressor again increasing the pressure and temperature of
the refrigerant.
A thermistor, which monitors the temperature of the air that has passed through the evaporator core, controls A/C
clutch cycling. If the temperature of the evaporator core discharge air is low enough to cause the condensed
water vapor to freeze, the A/C clutch is disengaged by the PCM.
The high-side line pressure is also monitored so that A/C compressor operation is interrupted if the system
pressure becomes too high or is determined to be too low (low charge condition).
The A/C compressor relief valve opens and vents refrigerant to relieve unusually high system pressure.

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Item Description

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1 A/C evaporator core

2 A/C evaporator core outlet temperature sensor

3 TXV

4 A/C charge valve port (low side)

5 A/C suction line

6 A/C compressor

7 A/C pressure relief valve

8 A/C pressure transducer

9 Low-pressure vapor

10 High-pressure vapor

11 Low-pressure liquid

12 High-pressure liquid

13 Compressor discharge line

14 A/C desiccant bag

15 A/C condenser core with A/C receiver/drier

16 Condenser-to-evaporator line

17 A/C charge valve port (high side)

Controls and Compressor Cycling

All customer commands for the EMTC climate control system come through the HVAC control head.

A/C Request

The HVAC module uses a dedicated wire to send the A/C request message to the BCM. The BCM sends the A/C
request through the HS-CAN to the PCM.
When an A/C request is received by the PCM, the PCM engages the A/C clutch relay when:

the refrigerant pressure isn't excessively high or low,

the engine coolant temperature isn't excessively high.

the ambient air temperature is above 6 C (42.8 F).

a WOT condition is not present.

the evaporator discharge air temperature is above 7.5 C (45.5 F).

Compressor Clutch

When A/C is requested and A/C line pressures allows, a ground is provided to the A/C clutch relay coil from the
PCM, energizing the A/C clutch relay. When the PCM energizes the relay, voltage is supplied to the A/C
compressor clutch field coil from the relay.

A/C Compressor Cycling

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The evaporator discharge air temperature sensor is an input to the BCM and is relayed to the PCM over the HS-
CAN. The evaporator discharge air temperature sensor prevents icing of the evaporator core by measuring the
temperature of the airflow immediately after the evaporator core. An accurate evaporator temperature is critical for
compressor engagement. The PCM uses the temperature measurement to regulate the on and off time of the A/C
compressor to maintain the evaporator temperature within an acceptable temperature range.
The PCM monitors the discharge pressure measured by the A/C pressure transducer. The PCM interrupts A/C
compressor operation in the event the A/C pressure transducer indicates high system discharge pressures. It is
also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient
temperature, the PCM does not allow the A/C clutch to engage.

Air Handling

Based on the climate control system temperature settings, the temperature blend door actuator directs airflow
through the evaporator and heater cores as needed. The defrost/panel/floor mode door actuator controls the
airflow to the defrost, floor or panel register vents. The air source is from outside air or recirculated passenger
compartment air as determined by the air inlet mode door position.
The defrost/panel/floor mode door and temperature blend door actuators use a potentiometer to sense and
communicate the door position to the HVAC module. When in airflow mode or desired driver or passenger
temperature is requested by the HVAC module, the appropriate door actuator motor is driven to the desired
position, using the position sensed by the door actuator potentiometer to accurately position the door actuator.
The blower motor is controlled using a blower motor resistor. The blower motor resister uses 3 resistors that are
wired in series on the ground side of the blower motor. The blower motor has 4 speeds:

for low speed, the all 3 resistors are used

for medium-low speed, 2 resistors are used

for medium-high speed, 1 resistor is used

for high speed, the blower motor is provided a path directly to ground and the blower motor resistor is not
used
The HVAC module grounds 1 of the 4 circuits to control the blower motor speed.

Control System Logic

The blower motor knob must be set to any speed other than 0 for the system to operate

MAX AC

When MAX A/C is selected:

the air inlet door closes, preventing outside air and admits only recirculated air.

the recirculated air indicator is illuminated (recirculated air forced on).

the A/C button is illuminated.

the A/C compressor operates if the outside temperature is above approximately 6 C (42.8 F).

PANEL

When PANEL mode is selected:

the mode doors direct airflow to the instrument panel registers.

the recirculated air request button can be enabled.

blended air temperature is available. The airflow temperature can only be cooled below the outside air
temperature when the A/C is commanded on.

PANEL-FLOOR

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When PANEL/FLOOR mode is selected:

the mode doors direct airflow to the floor duct and the instrument panel registers. A small amount of airflow
from the side window demisters and defrost duct is present.

the recirculated air request button can be enabled.

blended air temperature is available. The airflow temperature can only be cooled below the outside air
temperature when the A/C is commanded on.

OFF

When the system is OFF:

the air inlet door closes, preventing outside air and allowing only recirculated air.

the blower motor is off.

FLOOR

When FLOOR mode is selected:

the mode doors direct airflow to the floor duct. A small amount of airflow from the defroster duct and side
window demisters is present.

the recirculated air request button can be enabled.

blended air temperature is available. The airflow temperature can only be cooled below the outside air
temperature when the A/C is commanded on.

FLOOR-DEFROST

When FLOOR/DEFROST mode is selected:

the mode doors direct airflow to the floor duct, the defroster duct and the side window demisters.

the recirculated air request button can be enabled, but can automatically turn off.

blended air temperature is available. The airflow temperature can only be cooled below the outside air
temperature when the A/C is commanded on.

DEFROST

When DEFROST is selected:

the mode doors direct airflow to the defroster duct and side window demisters. A small amount of airflow from
the floor duct is present.

the recirculated air request button can be enabled, but can automatically turn off.

the A/C is automatically commanded on and will remain on until the system is either turned off or the airflow
mode has changed and A/C button is pressed.

blended air temperature is available.

Component Description

Heating Ventilation Air Conditioning (HVAC) Module - Electronic Manual Temperature Control
(EMTC)

The blower motor speed switch is mounted in the HVAC module and controls blower motor speed by adding or
bypassing resistors in the blower motor resistor in all modes except OFF. The blower motor speed switch is
serviced only as an assembly with the HVAC module.

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The temperature control switch adjusts the discharge air temperature. Movement of the temperature knob from
cool to warm causes a corresponding movement of the temperature blend door. The position of the temperature
blend door determines the discharge air temperature. The temperature control selector is an integral part of the
HVAC module and cannot be serviced separately.
The airflow mode setting adjusts the discharge air outlet location. Each airflow mode selector icon causes a
corresponding movement of the airflow mode doors and determines the discharge air outlet location. The airflow
mode selector knob is an integral part of the HVAC module and cannot be serviced separately.
The A/C button determines A/C compressor operation, except when the temperature selector is set to MAX A/C
or the airflow mode selector is in defrost mode. The A/C button is an integral part of the HVAC module and cannot
be serviced separately.
The recirculated air request button can be activated in any mode except defrost, and in any mode except MAX
A/C. The recirculated air request button is an integral part of the HVAC module and cannot be serviced
separately.

Air Conditioning (AC) Pressure Transducer

The PCM monitors the discharge pressure measured by the A/C pressure transducer. As the refrigerant pressure
changes, the resistance of the A/C pressure transducer changes. It is not necessary to recover the refrigerant
before removing the A/C pressure transducer.
A 5-volt reference voltage is supplied to the A/C pressure transducer from the PCM. The A/C pressure transducer
receives a ground from the PCM. The A/C pressure transducer then sends a voltage to the PCM to indicate the
A/C refrigerant pressure.

Evaporator Temperature Sensor

The evaporator discharge air temperature sensor contains a thermistor. The sensor varies its resistance with the
temperature. As the temperature rises, the resistance falls. As the temperature falls, the resistance rises.

Defrost-Panel-Floor Mode Door Actuator

The defrost/panel/floor mode door actuator contains a reversible electric motor and potentiometer. The
potentiometer allows the HVAC module to monitor the position of the airflow mode door. The HVAC module
drives the actuator motor in the direction necessary to move the airflow mode doors to the position set by the
mode selector knob.

Temperature Blend Door Actuator

The temperature blend door actuator contains a reversible electric motor and potentiometer. The potentiometer
allows the HVAC module to monitor the position of the temperature blend door. The HVAC module drives the
temperature blend door actuator motor in the direction necessary to move the temperature blend door to the
position set by the temperature selection knob.

Air inlet Mode Door Actuator

The air inlet mode door actuator moves the air inlet door between the fresh and recirculated air positions on
command from the HVAC module. The air inlet mode door actuator is driven to, and will automatically stop at, the
full recirculated air or full fresh air inlet position and does not require a potentiometer circuit to monitor its position.
The airflow mode door does not stop at any point between the recirculated air or fresh air inlet position.

Air Conditioning (AC) Compressor Clutch

When battery voltage is applied to the A/C compressor clutch field coil, the clutch disc and hub assembly is drawn
toward the A/C clutch pulley. The magnetic force locks the clutch plate and hub assembly and the A/C clutch
pulley together as one unit, causing the compressor shaft to rotate with the engine. When battery voltage is
removed from the A/C compressor clutch field coil, springs in the clutch plate and hub assembly move the clutch

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plate away from the A/C clutch pulley.

An A/C clutch diode is integrated into the coil. For A/C clutch field coil circuit spike suppression.

Air Conditioning (AC) Compressor

The A/C compressor has:

a non-serviceable shaft seal.

a pressure relief valve installed in the rear of the compressor to protect the refrigerant system against
excessively high refrigerant pressures.

PAG oil or equivalent. This oil contains special additives required for the A/C compressor. The oil may have
some slightly dark-colored streaks while maintaining normal oil viscosity. This is normal for this A/C
compressor because of break-in wear that can discolor the oil.
Use the oil adding procedure specified for this vehicle when installing a new A/C compressor. REFER to
Refrigerant Oil Adding.

Air Conditioning (AC) Condenser

The A/C condenser is an aluminum fin-and-tube design heat exchanger. It cools compressed refrigerant gas by
allowing air to pass over fins and tubes to extract heat, and condenses gas to liquid refrigerant as it is cooled.

Evaporator Core

The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core housing.
A mixture of liquid refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet
tube and continues out of the evaporator core through the evaporator core outlet tube as a vapor. During A/C
compressor operation, airflow from the blower motor is cooled and dehumidified as it flows through the evaporator
core fins.

Thermostatic Expansion Valve (TXV)

The TXV is located at the evaporator core inlet and outlet tubes at the center rear of the engine compartment. The
TXV provides a restriction to the flow of refrigerant and separates the low-pressure and high-pressure sides of the
refrigerant system. Refrigerant entering and exiting the evaporator core passes through the TXV through 2
separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out of
the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core.
The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower
temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures.

Receiver-Drier

The receiver/drier is integral to the A/C condenser. It stores high-pressure liquid refrigerant after it leaves the
condenser core.
The receiver/drier is incorporated onto the LH side of the A/C condenser. The receiver/drier desiccant bag is a
separate component and can be separately removed and installed with the A/C condenser removed from the
vehicle.

Service Gauge Port Valves

The service gauge port fitting is an integral part of the refrigerant line or component.

Special couplings are required for both the high-side and low-side service gauge ports.

A very small amount of leakage is always detectable around the Schrader-type valve with the service gauge
port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the
seal leaks excessively.

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The A/C service gauge port valve caps are used as primary seals in the refrigerant system to prevent
leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C
service gauge port valve caps to the correct torque after they are removed.

Item Service Part Number Description

1 19D702 Low-pressure service gauge port valve cap

2 — Low-pressure service gauge port valve

3 19D701 Low-pressure Schrader-type valve

4 19D701 High-pressure Schrader-type valve

5 — High-pressure service gauge port valve

6 19D702 High-pressure service gauge port valve cap

Refrigerant System Dye

A fluorescent refrigerant system dye wafer is added to the receiver/drier desiccant bag to assist in refrigerant
system leak diagnosis using a Rotunda-approved UV blacklight. This fluorescent dye wafer dissolves after about
30 minutes of continuous A/C operation. It is not necessary to add additional dye to the refrigerant system before
diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Additional
refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has
been lost due to a fitting separation or hose rupture.

Blower Motor Resistor

The blower motor resistor uses 3 resistance elements mounted on a resistor board to provide 4 blower motor
speeds. Depending on the heater blower motor switch position, series resisters are added or bypassed in the
blower motor resistor to decrease or increase blower motor speed.

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Copyright © 2012 Ford Motor Company

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