Ford Workshop Service and Repair Manuals

For the Cougar two control units are available.

Vehicles without air conditioning (A/C) have the same control unit with three rotary switches, as fitted in the Mondeo. The temperature valve is actuated mechanically by means of a Bowden cable. The air distribution is vacuum-controlled.

When the air distribution control switch is in the ”OFF" position, the blower motor is also switched off regardless of the blower switch setting.

Control unit (vehicles without A/C)

The control unit for vehicles with SATC has two rotary switches, four buttons and a display.

The air distribution control switch performs the same functions as the other control unit, but additionally reports the position of the flap setting (defrost only) to the microprocessor.

The buttons are used to select A/C and recirculated air mode and to select ”warm" or ”cold" air at temperatures from 18-29°C in 1° steps. Above and below these settings are the HI and LO settings which allow a minimum temperature of 15°C and a maximum temperature of 32°C to be set. The self-test can also be actuated by using a combination of these buttons.

The display shows the selected temperature, A/C and recirculated air mode and displays the fault codes in self-test mode.

Control unit (vehicles with SATC)

Semi-Automatic Temperature Control

A microprocessor inside the control unit evaluates the following input parameters and the signals emitted by the associated sensors:

• The selected settings on the control unit (temperature, air conditioning on/off, recirculated air mode, air distribution and blower speed).
• Passenger compartment temperature
• Ambient temperature
• Coolant temperature
• Sun load
• Vehicle speed

The following illustration shows the flow of signals to and from the control unit.

Signal flow

• In automatic mode, the blower speed varies according to the ambient temperature and a preset delay factor.
• Temperatures between 18°C and 29°C can be selected in 1° steps. Pressing the red button increases the temperature, whilst pressing the blue button reduces it. The system controls the temperature flap and the blower speed accordingly.
• A self-test can be called up by pressing a combination of buttons ( For additional information, refer to Section  412-00 Climate Control System - General Information.).

Additional technical features of the control units.

• LO setting (15°C) gives continuous cooling, HI setting (32°C) gives continuous heating.
• A/C button - pressing this button switches the air conditioning alternately on and off (depending on the current operating mode).
• RECIRCULATED AIR button - each time this button is pressed, the system switches from recirculated to fresh air or vice versa (depending on the current operating state).
• AIR DISTRIBUTION switch - to select the desired air distribution setting. In the DEMIST setting, the air conditioning automatically switches to fresh air mode. In the OFF setting, the fresh air flap (recirculated air mode) closes, and the blower motor and air conditioning controls will not function.

If the BLOWER regulator is switched out of the AUTO setting, the blower speed is no longer automatically regulated. It is then set manually by turning the regulator switch.

• In automatic mode, the blower is set to the optimum speed for the system's requirements.
• When it is set manually, the blower speed remains constant (depends on regulator switch position).

Operation

The Semi-Automatic Temperature Control (SATC) system automatically keeps the temperature constant at the level selected for optimum driving comfort and controls the supply of air to the following components:

• heat exchanger,
• heating ducts in footwell,
• windshield demister nozzles,
• side window demister nozzle.

The system incorporates the following control elements or functions:

• Switch for manual adjustment of the air distribution.
• Regulator for setting the blower speed manually or automatically.
• Sun load sensor which automatically measures the level of sunshine so that it can compensate for the resulting rise in temperature.
• Optimum operation is achieved in AUTO mode, where only the desired temperature is selected.
• If the passenger compartment temperature is lower than the selected temperature, the system automatically activates the heating (only when the engine is hot ) in order to reach the selected temperature as quickly as possible.
• The air conditioning should be switched on if the ambient temperature is higher than 15°C or the passenger compartment temperature is higher than the selected temperature.
• Only change the selected temperature in gradual stages (1-2°C). This prevents large fluctuations in the passenger compartment temperature. Increasing the selected temperature by a large amount does not reduce the time it takes to reach the desired temperature.

Digital display

Depending on the selected setting, the digital display displays one of the following values:

• Selected A/C mode and/or recirculated air mode and selected temperature.
• No display in the OFF setting.

Blue button (lower temperature)

The blue button is for reducing the temperature and works as follows:

• Pressing the button once reduces the temperature by 1°C.
• Pressing and holding the button down reduces the temperature in 1° steps as far as 18°C and in the next step to LO (15°C), i.e. maximum cooling capacity (continuous cooling).

Red button (increase temperature)

The red button is for increasing the temperature and works as follows:

• Pressing the button once raises the temperature by 1°C.
• Pressing and holding the button down increases the temperature in 1° steps as far as 29°C and in the next step to HI (32°C), i.e. maximum heating capacity (continuous heating).

A/C button

• Pressing the button switches the air conditioning relay together with the A/C symbol alternately on and off (depending on the current operating state).
• The air conditioning relay will not come on if the ambient temperature is below -2°C. If the A/C button is then actuated, the A/C symbol will flash to indicate this.
• The A/C symbol reappears when the temperature reaches 2°C, provided that the air conditioning relay has come on.
• In the DEMIST setting, the air conditioning relay is permanently on. The ambient temperature determines whether or not the A/C symbol is displayed.

Recirculated air button

• Pressing this button switches the recirculated air solenoid together with the recirculated air symbol alternately on or off (depending on the current operating mode).
• If the ambient temperature is over 2°C, the A/C symbol switches on and off together with the air conditioning relay. If the A/C symbol and air conditioning relay were already switched on, they remain switched on. Both of them remain switched on after recirculated air mode is switched off.
• If the ambient temperature is below -2°C, the A/C symbol will not appear. The air conditioning relay will not switch on.
• The recirculated air function is not available during demisting. If the recirculated air button is then actuated, the recirculated air symbol will flash to indicate this.

Air distribution switch

Face level only

The main airstream enters the passenger compartment at face level.

Footwell and face level

The main airstream is divided equally between the foot and face level vents, and a small amount of air is directed to the side window demister nozzles.

OFF

In the OFF position, the air conditioning is completely switched off (the digital display is blank). The fresh air flap is closed (recirculated air mode).

Footwell

The main airstream is directed into the footwells, and a small amount of air is directed to the windshields and the side window demister nozzles.

Demist/footwell

The main airstream is equally divided between the windshield and the footwell vents, and a small amount of air is directed to the side window demister nozzles.

Demist

The main airstream is directed onto the windshield, and a small amount of air is directed to the footwells and the side window demister nozzles. The air conditioning relay is permanently on, the A/C symbol is displayed depending on the ambient temperature, and recirculated air mode is not available.

Blower regulator

If the regulator is moved out of the AUTO setting by turning it more than 10 degree in the clockwise direction, automatic blower control is swiched off and the blower speed can be set manually. The blower speed is increased by turning the regulator clockwise and decreased by turning it anti-clockwise. To return to automatic mode, turn the regulator back to AUTO.

Automatic mode

Automatic mode (semi-automatic temperature control) is switched on by:

• Setting the blower regulator to AUTO and pressing the A/C button. The ambient temperature must be higher than 2°C.
• The selected temperature and A/C symbol appear on the digital display.
• The selected temperature is kept constant by:
  -

  Regulating the volume of air (blower speed),
  -

  Regulating the temperature of the emerging air by means of the temperature flap.
• For warm air, direct the main airstream into the footwells (air distribution switch to footwell setting). A small amount of air will be directed to the windshield and side window demister nozzles.
• For cool air, direct the main airstream to the face level vents (air distribution switch to face level setting). The nozzles are adjustable. When the maximum cooling level is reached, the system automatically switches to recirculated air mode (if the air conditioning relay is switched on) and switched back automatically to fresh air mode when the selected passenger compartment temperature is reached.
• In cold weather, the blower does not come on immediately after starting the engine, but only once the coolant reaches a temperature of 42°C, but not later than 3,5 minutes after starting the engine.

Pulse Width Modulator (PWM)

The pulse width modulator (PWM) module is used to regulate the blower motor speed and is located behind the blower housing.

The PWM supplies the blower motor with pulses of variable width at a constant voltage. Narrow pulses make the blower motor rotate slowly and wide pulses result in high speeds. The PWM is actuated by switching on and off an actuating voltage (5 Volts) at 2000 Hz. The SATC control unit tells the PWM the required blower speed by changing the ratio between ON and Off time.

The PWM regulates the blower speed and has an overload cut-off switch which protects the blower motor from overheating and damage if a blockage occurs.

Temperature flap control motor

The temperature flap control motor is located on the inside of the evaporator housing and is connected to the temperature flap.

• It adjusts the position of the temperature flap in response to the signals sent by the control unit.
• The temperature flap control motor consists of a reversible electric motor and a potentiometer. The potentiometer slide is connected to the output shaft and moves together with it in order to report the flap position back to the control unit.
• The potentiometer is supplied with 5 V. The slide uses a certain proportion of this voltage, depending on the flap position. This is amplified and sent back to the control unit, thus informing the control unit of the current flap position. The control unit controls the temperature flap control motor so that goes in the right direction to achieve the required temperature.

Sun load sensor

The sun load sensor is located on the driver side at the top of the instrument panel.

• It measures the intensity of the sunshine.
• The sun load sensor contains a photoelectric cell whose resistance decreases as the sun load increases.
• The photoelectric cell is part of a voltage distributor which is supplied with a voltage of 5 V. The voltage at the photoelectric cell is a measure of the sun load and is sent to the control unit. The microprocessor in the control unit compensates for the sunshine in two ways: by adjusting the position of the air mixing flap and/or increasing the blower speed.

Passenger compartment temperature sensor

The passenger compartment temperature sensor is incorporated in the instrument cluster.

• It measures the current temperature in the passenger compartment.
• It contains an electrically driven blower which sucks in air from the passenger compartment and directs it over an NTC element.
• The resistance of the NTC element decreases as the temperature increases. The blower is supplied with 12 V directly from the control unit. The NTC element is part of a voltage distributor which is supplied with a voltage of 5 V. The voltage drop at the NTC element is a measure of the passenger compartment temperature.
• This voltage is passed on to the control unit which adjusts the required passenger compartment temperature accordingly.

Engine coolant temperature sensor - air conditioning (ECT sensor)

The ECT sensor is located in the feed pipe to the heat exchanger.

• It measures the coolant temperature.
• The ECT sensor contains an NTC element. The resistance of the NTC element decreases as the temperature increases.
• The sensor is part of a voltage distributor which is supplied with a voltage of 5 V. The voltage at the NTC element is a measure of the coolant temperature. This voltage is passed on to the control unit, which increases the blower speed if the coolant temperature is low.

Ambient temperature sensor

The ambient temperature sensor is installed in the front bumper.

• It measures the external temperature.
• The ambient temperature sensor contains an NTC element. The resistance of the NTC element decreases as the temperature increases.
• The sensor is part of a voltage distributor which is supplied with a voltage of 5 V. The voltage at the NTC element is a measure of the ambient temperature. This voltage is passed on to the passenger compartment temperature.

Recirculated air solenoid

The recirculated/fresh air solenoid is fitted to the evaporator housing.

• It blocks or releases the vacuum to the recirculated air flap vacuum actuator.
• It consists of a magnetic switch which operates a valve.
• The recirculated/fresh air solenoid is supplied with a voltage of 12 V. The control unit switches it on by connecting its circuit to ground (GND). To switch it off, the circuit is disconnected from ground.

Air distribution switch

The air distribution switch is part of the control unit.

• It directs the main airstream to the selected outlet(s).
• The air distribution switch combines electrically and pneumatically controlled functions. The air distribution is controlled pneumatically.
• In the OFF setting, the control unit and blower are switched off. In the DEMIST setting, a signal is sent to the control unit to disable RECIRCULATED AIR mode and switch on the air conditioning. Both functions are controlled electrically and pneumatically.

Vacuum diagram