FG 5.0 WSM - Page 1 of 5

412-00

Climate Control System - General Information

Section: 412-00 climate control System -

General information

VeHicLe APPLicAtion: 2010.0 FPV 5.0L 4V ti-Vct V8

contentS

PAGe

DeScRiPtion AnD oPeRAtion

Climate Control System ...........................................................................................................................412-00-1

Heating, Ventilation and Air Conditioning (HVAC) Assembly .............................................................412-00-1

HVAC Case ................................................................................................................................................412-00-1

Control Components ...............................................................................................................................412-00-1

Air Distribution ...........................................................................................................................................412-00-2

Air Conditioning ........................................................................................................................................412-00-3

DiAGnoSiS AnD teStinG

Acronyms and Abbreviations .................................................................................................................412-00-4

Version: 2010.0 FPV 5.0L 4V Ti-VCT V8

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Climate Control System - General Information

412-00-1

DeScRiPtion AnD oPeRAtion

climate control System

A filter mesh is standard, but a pollen filter is optional.

The 2010 FPV 5.0L is fitted with either a Single Zone

HVAc

Details

(SZ) or a Dual Zone (DZ) Automatic Climate Control

interface

(ACC) heater/ventilation/air conditioning (HVAC) unit

Mount

3 nuts - HVAC to Cowl

with manual overrides possible. Dual zone allows

Points

different comfort settings for driver and passenger.

1 nut - HVAC to Dash

The 2010 FPV 5.0L Air Conditioning system is a

2 bolts - HVAC to Floor Bracket

new system featuring a number of upgrades and

Sound

Integrated assembly with HVAC -

improvements compared to the 2008 system.

Insulator

Fixing posts on case, locating guide

The system is a Clutch Cycling Thermal Expansion

ribs around all pass throughs have

Valve (TXV) system with a sub cooled condenser.

been removed to allow the use of

The system features a new compressor, improved

larger stepped seals. Spacer clips on

condenser design and improved system joint design.

upper middle and upper right mount

The major components in the 2010 FPV 5.0L A/C

points replace fir tree clips used on

system are NOT compatible with he 2008 FG Falcon.

2006 BF Falcon vehicles.

Heating, Ventilation and Air conditioning

Drain

Solid drain on centreline with

(HVAc) Assembly

laminated foam seal. Interfaces to

separate drain tube assembled into

The 2010 model year Falcon Heating, Ventilation

horizontal section of dash panel

and Air Conditioning (HVAC) assembly is similar in

specification to the 2008 FG Falcon. However, the

control components

HVAC unit differs in some areas and should not be

The HVAC unit incorporates a HIM (HVAC Integrated

fitted into the 2008 FG Falcon.

Module) that controls all aspects of the HVAC's

HVAc case

operation.

The 2010 Falcon HVAC case has a number of

The 2010 Falcon HVAC Integrated Module (HIM)

features which are similar to the 2008 FG Falcon.

has been updated with two new software genders,

These include:

including:

Evaporator assembly with 38mm thick core

Single Zone Automatic HVAC and

Evaporator tube end fittings to suit the Thermal

Dual Zone Automatic HVAC

Expansion Valve (TXV), with new refrigerant

NOTE: The heater Only Manual HVAC software

O-rings

gender is not provided in the 2010 V8 HIM.

Stepped evaporator seals (to interface to a new

The 2010 Falcon HIM unit should not be fitted into

dash inner Insulator)

the 2008 FG Falcon vehicles. The 2010 FPV HIM can

Evaporator thermistor (temperature sensor) with

now be removed for service without removing the

angled plastic housing and bayonet type fitting

entire instrument panel (IP). Instead, the LH lower IP

into HVAC case

finish panel that incorporates the glove box can be

removed to give access to the HIM.

Evaporator thermistor switching software

The HIM is connected to the HS-CAN (High Speed

Three HVAC Integrated Module (HIM) genders

Controller Area Network) serial data bus through

An additional condensate drain tube is fitted into the

which flows all sensor and command inputs required

floor panel, below the HVAC assembly drain outlet.

to operate the climate control system.

This has been carried over from the 2008 Falcon.

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Climate Control System - General Information

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DeScRiPtion AnD oPeRAtion (continued)

Operator commands are input into the ICC. The ICC

The Cabin Temperature Sensor (CTS) in the 2010

then passes the command input through the MS-

FPV Falcon has new hardware and software, and

CAN (Medium Speed CAN), to the HSCAN (through

is not interchangeable with the FG Falcon CTS. The

a gateway in the Cluster) to the HIM. The HIM takes

cabin temperature sensor is located behind a small

the information and performs the required actions

grille in the centre of the ICC (Interior Command

and outputs the appropriate information for the ICC

Centre) switches directly below the audio system.

display screen (Face Display Module FDM). The

The CTS reading is used by the ACC climate control

HIM also monitors some vehicle operating data for

system to maintain the comfort setting. The cabin

optimisation of Climate Control System performance.

temperature sensor is part of the ICC main PCB and

is wired directly to the BEM. The 2010 FPV cabin

Feature

Details

temperature sensor is not serviceable as a separate

component (if the CTS is faulty, the complete ICC

Mode Actuation

Electric - Integrated HIM module

must be replaced). The new CTS does not need to

Air Mix Actuation

Electric - Integrated HIM module

be recalibrated when the ICC or BEM is replaced.

Low Series

The combined Twilight and Sun Load sensor is

Air Mix Actuation

Electric - Integrated HIM module

unchanged from the 2008 FG Falcon, and is still

High Series

+ DZ actuator

located in the top of the instrument panel between

Control Logic

Intelligent software control

the passenger and driver screen air duct. The sensor

Low Series

incorporated into HIM

is wired directly to the BEM. The Sun Load sensor

is used by the ACC climate control system only, to

Control Logic

Intelligent software control

adjust the ACC for different sun intensity levels. The

High Series

incorporated into HIM

Twilight Sensor provides information about low light

Blower Fan

10 detent fan speed control

conditions for automatic headlight operation.

Control Heater

integrated in HIM

The Ambient temperature sensor in the 2010 FPV

Only

Falcon is located in the passenger side external

Blower Fan

Continuously variable fan speed

mirror housing and is wired directly to the HIM. It is

Control Low and

control integrated into HIM,

used by the ACC climate control system only. The

High Series

AUTO mode

Ambient Temperature sensor is not a serviceable

10 detent fan speed control

item. If the sensor is faulty, the complete LH external

integrated in HIM, manual

mirror assembly should be replaced.

overide

Air Distribution

Dual Zone

Yes

The 2010 FPV Falcon carries over the air distribution

ACC Compatible Yes

system from the 2008 FG Falcon. The air distribution

A/C

Yes - software strategy to

system features face, console and rear passenger

Performance

detect A/C performance

ducting, Instrument Panel registers (rear console

Monitor

degradation

demist vent and side window vents.

A/C

Yes

Compressor

The HVAC unit features heating and cooling to the

Protection

rear occupants through the console if the Face, Foot,

Face/Foot split or Demist/Foot split mode is selected

Both the HIM and the PCM have new software to

by the front occupants.

control the ACC system and to protect the A/C

compressor.

Airflow to the rear is maintained in all modes except

full demist.

In the automatic climate control (ACC) system,

the climate control system automatically adjusts

the operation mode of the HVAC to provide a set

comfort under all operating conditions.

Dual zone allows different comfort settings for driver

and passenger. Manual over-ride of automatic

control mode is able to be selected at any time.

In the ACC system, each individual remote key

transmitter retains the Climate Control temperature

settings previously selected when that remote key

was last used.

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Climate Control System - General Information

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DeScRiPtion AnD oPeRAtion (continued)

Air conditioning

end similarly features an O-ring together with slimline

sealing washer. The suction hose is retained in the

The 2010 Falcon Air Conditioning system is a new

vehicle by a metal bracket and bolt along with the

system featuring an upgrade in technology. The

refrigerant pad fittings.

major components in the 2010 Falcon A/C system

The 2010 FPV features a new compressor discharge

are NOT compatible with the 2008 FG Falcon

hose assembly. The compressor discharge hose

system.

assembly features both an O-ring and slimline sealing

The 2010 Falcon A/C system requires slightly

washer at both the compressor pad fitting and

more refrigerant charge than the 2008 FG Falcon.

condenser inlet fitting. The compressor discharge

Note that incorrect refrigerant charge can cause

hose is retained in the vehicle by a metal bracket and

excessively high discharge pressures resulting

bolt along with the refrigerant pad fittings.

in compressor damage, compressor cut-out,

The 2010 FPV features revised locations for the two

excessive operating noise or poor A/C performance.

refrigerant charge ports. There is a high pressure

The TXV modulates the refrigerant flow in the circuit

discharge port adjacent to the PCM and a low

via a variable orifice opening and, combined with

pressure suction port located close to the suction

the sub cooled condenser, eliminates the need for

sub-tube outlet on the manifold.

a suction accumulator. This TXV replaces the fixed

The 2010 Falcon Air Conditioning system contains

opening Orifice Tube that has been used on previous

new dual slimline joint seals. These seals use an

Falcon models.

O-ring similar to the 2008 Falcon system together

The 2010 compressor is a new design with new

with a new slimline washer that has an integral sealing

operating characteristics and new mounting points.

gasket. This provides 2 separate sealing surfaces

The compressor contains a new oil specification and

to help improve system sealing performance. For

quantity. It is a new deign and not interchangeable

further information on the service requirements

with the 2008 FG Falcon.

for these dual slimline joints, refer to Removal and

Installation in this section.

The bracket supporting the 2010 A/C compressor

also supports the power steering pump.

Quick joint connections are not used in the 2010 FPV

Falcon Air Conditioning system.

The 2010 A/C condenser assembly is different in

construction, size, mounting points, inlet/outlet

fittings and operating characteristics to the 2008 FG

condenser assembly. The condenser uses a new

mounting strategy that employs vertical brackets with

sprung retaining clips which are moulded into the

radiator assembly. The new sub-cooled condenser

features an integral receiver/modulator with a

serviceable filter/drier assembly. An access door is

provided in the lower air deflector assembly for easy

access to the filter/drier.

The 2010 FPV Falcon features new refrigerant

lines. The liquid line and suction sub tube are joined

together to form a dual tube assembly. This dual

tube assembly is retained in the vehicle by 2 plastic

clips and 1 metal bracket with bolt in addition to the

refrigerant fittings. The new liquid line assembly

includes a 19mm (OD) (low pressure sub tube)

brazed onto an 8.5mm (OD) tube with a hose section

just before the condenser outlet joint. In addition,

the new liquid line assembly also includes a manifold,

TXV and the required hardware (2 x M5 & M8 bolts)

to secure the assembly to evaporator tubes using an

E-clamp (similar to FG) with two M5 threaded holes.

The pad fittings to the suction hose assembly and

condenser outlet both feature O-rings together with

slimline sealing washers. The connections to the TXV

valve feature slimline sealing washers only.

The 2010 FPV Falcon features a new suction hose

and tube assembly. The suction hose and tube

assembly joins to the dual tube assembly with a

pad fitting featuring both an O-ring and slimline

sealing washer. The pad joint at the compressor

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DiAGnoSiS AnD teStinG

Acronyms and Abbreviations

Note: The following acronyms will be used

throughout this section.

A/C

Air Conditioning

ACC

Automatic Climate Control

ACPT

Air Conditioning Pressure Transducer

BEM

Body Electronics Module

CAN

Controller Area Network

CTS

Cabin Temperature Sensor

DTC

Diagnostic Trouble Code

Dual Zone

ECU

Electronic Control Unit

EEC

Electronic Engine Control (part of PCM)

EVT

Evaporator Vent Temperature

FDM

Face Display Module

HIM

HVAC Integrated Module

HTR

Heater

HVAC

Heating, Ventilation & Air Conditioning

Assembly

ICC

Interior Command Centre

MAX

Maximum

MCC

Manual Climate Control

MIN

Minimum

MSG

Message

N/A

Not Applicable

PCM

Powertrain Control Module

PID

Parameter Identifier

RPM

Revolutions Per Minute

Single Zone

TXV

Thermal Expansion Valve

Version: 2010.0 FPV 5.0L 4V Ti-VCT V8