1998 Ford Escort Malfunction - Heating & Cooling System

Question: I have a '98 Escort Wagon. About four years ago, the a/c failed, and I went about a year before having anyone look at it (I live in Ontario, and can manage OK without it). Eventually, a mechanic told me that a major control module was faulty, and it would be about $300 to replace it. I didn't bother. But last year, the a/c suddenly came on, and blew nice cool air for about an hour, until I shut the car off. Since then, it hasn't worked again. I'm wondering if it's something relatively simple like a dirty master relay contact or connector. Can you tell me where to find the a/c master relay?

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Technican: All relays should be labeled on the relay cover. Have you checked to see if the A/C compressor is cycling on when you turn on the A/C on?

Owner: The compressor doesn't appear to be coming on. That is, with the engine running, there is no change in sound from the compressor when the a/c switch is "on". No click, no whirr, and no nasty smells. Relay box is near the battery, right?

Technican: Underhood anyway, if there is no relay for the A/C and the fuse tests okay, the only thing left you can check is the low pressure switch. This switch shuts down the compressor when low pressure is observed to prevent damaging compressor (system pressure consists of refrigerant and oil to lube the system) because of lack of oil in the system. If there is no relay the system is controlled by one of fords infamous modules (likely called a GEM module on your car). Does GEM module sound familiar?

Owner: Yes, GEM sounds familiar. Generic Electronic Module, isn't it? But I didn't think the GEM inlcuded A/C control. Maybe I'm wrong. The A/C fuse is OK, and I haven't found an A/C relay, which is a surprise. How do they switch on the compressor clutch without a relay; a big transistor? Do you have any idea where I'd find the pressure sensor switch?

Technican: There are a few different modules Ford uses, GEM is the most common. Use the followong link to access a repair guide for your car. It should have the low pressure sensor switch location (with an image) as well as a wiring diagram for the system. autozone.com/servlet/UiBroker?UseCase=RG001&UserAction=viewRepairGuideYMMEYear

Owner: thanks for the link to a useful guide. Unfortunately, the section on air conditioning is very short, and simply says "Repair or service of air conditioning components is not covered by this guide, because of the risk..."

Technican: The following link is supposed to contain the troubleshooting procedure for the CCR Module- I cannot view the link because it requires Adobe Acrobat Reader which I have been unable to access. 4s.com/fourseasons/tech_tips/tech_tips_english/AB363_97_and_Newer_CCRM_03.pdf Let me know what you find.

Owner: Douglas. That link looks like it will be really useful. I also found a tech tip at the same site regarding testing of the integrated relay control module. Once I locate that module on my car, I will go through their diagnostic. Do you know where it is located? For your convenience, I've posted GIF versions of both those documents at home.golden.net/~malton/jmalton/ford-tips/ Your browser should be able to open those by itself.

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