Contents Section: A/c Compressor All sections

Heating, Ventilation & Air Conditioning Hyundai Santa Fe I

A/c Compressor 89 illustrations ~4457 words

SPECIFICATION

ItemSpecification
HeatingHeater
TypeAir mix type
Air conditioningEvaporator
Cooling capacity4,400Kcal/h (17,460 BTU/h)
Compressor
Type Lubricating oil Oil capacity Refrigerant & capacity Displacement Pressure relief valveSwash plate (HS-18) FD46XG (PAG) 150 +/- 10cc R-134a (600 +/- 25g) 180 cc/rev Working pressure: 35.0 ~ 42.2kg/cm 2 Resealed pressure: Min. 28.1 kg/cm 2
Magnetic clutch
Pulley pitch dia. Voltage & wattage TorqueDiameter 130 D.C. 12.8V, Max. 46W Min. 4.0kg.m
Triple pressure switchHigh pressure ON 32.0 +/- 2.0kg/cm 2 OFF 26.0 +/- 2.0kg/cm 2
Middle pressure ON 18.0 +/- 0.8kg/cm 2 OFF 14.0 +/- 1.2kg/cm 2
Low pressure ON 2.3 +0.25, -0.29kg/cm 2 OFF 2.0 +/- 0.2kg/cm 2
Heater control assemblyMANUAL Type, AUTOMATIC Type

AIR CONDITIONING SPECIFICATION

LUBRICANTS

ItemRecommended lubricantQuantity
Heater control leverMultipurpose greaseAs required
Compressor oilPAG (poly alkylene glycol) oil FD46XG or equivalent150 +/- 10cc

RECOMMENDED LUBRICANTS

SPECIAL TOOLS

SPECIAL TOOLS DESCRIPTION Tool (Number and name) Illustration Use 09977-29000 Pressure plate bolt remover Removal and installation of pressure plate 09455-34000 Bearing and gear puller Removal of field coil

Scheme 1

Scheme 1: SPECIAL TOOLS

PRECAUTIONS

The air conditioning system uses R-134a refrigerant and FD46XG (PAG) refrigerant oil, which are not compatible with R-12 refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do not attempt to use R-12 servicing equipment; damage to the air conditioning system or your servicing equipment will result.

CAUTIONAir conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. Be careful when connecting service equipment. Do not breathe refrigerant or vapor.

If accidental system discharge occurs, ventilate work area before resuming service.

R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air.

WARNINGCompressed air mixed with R-134a forms a combustible vapor. The vapor can burn or explode causing serious injury. Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

  1. Always disconnect the negative cable from the battery whenever replacing air conditioning parts.
  2. Keep moisture and dirt out of the system, When disconnecting any lines, plug or cap the fittings immediately; don't remove the caps or plugs until just before you reconnect each line.
  3. Before connecting any hose or line, apply a few drops of refrigerant oil to the O-ring.
  4. When tightening or loosening a fitting, use a second wrench to support the matching fitting.
  5. When discharging the system, use a R-134a refrigerant recovery/recycling/charging station; don't release refrigerant into the atmosphere.

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.

STANDARD

SymptomSuspect AreaRemedy
No blower operationHTR FuseReplace
Blower relayReplace
Blower motorReplace
Blower resistorReplace
Blower speed control switchReplace
Wire harnessReplace
No air temperature controlEngine coolant capacityAdd coolant
Heater control assemblyReplace
No compressor operationRefrigerant capacityAdd refrigerant
A/C FuseReplace
Magnetic clutchReplace
CompressorReplace
Triple pressure switchReplace
A/C switchReplace
ThermistorReplace
Wire harnessReplace
No cool comes outRefrigerant capacityAdd refrigerant
Refrigerant pressureApply a vacuum and add refrigerant
Drive beltAdjust
Magnetic clutchReplace
CompressorReplace
Triple pressure switchReplace
ThermistorReplace
A/C switchReplace
Heater control assemblyReplace
Wire harnessReplace
Insufficient coolingRefrigerant capacityAdd refrigerant
Drive beltAdjust
Magnetic clutchReplace
CompressorReplace
CondenserReplace
Expansion valveReplace
EvaporatorReplace
Refrigerant linesReplace
Triple pressure switchReplace
Heater control assemblyReplace
No engine idle-up when A/C switch ONEngine (and ECT) ECU
Wire harnessReplace
No air inlet controlHeater control assembly, cable, doorReplace
No mode controlHeater control assembly, cable, doorReplace
No condenser fan operationECU-IG FuseReplace
Fan motorReplace
Engine (and ECT) ECU
Wire harnessReplace

PROBLEM SYMPTOMS REFERENCE

SELF-DIAGNOSIS

The Full Automatic Temperature Control (FATC) module self test feature will detect electrical malfunctions and provide error code for system components with suspected failures.

Scheme 2

Scheme 2: CONTROL PANEL

Scheme 3

Scheme 3: SELF-DIAGNOSIS METHOD

Scheme 4

Scheme 4: HOW TO READ SELF-DIAGNOSTIC CODE
  1. After the display panel flickers three times every 0.5 second, the corresponding error code flickers on the setup temperature display panel every 0.5 second and will show two figures.
  2. If error code is more than two, each code flicker 2 times in sequence.

Scheme 5

Scheme 5: FAULT CODE DISPLAY

Scheme 6

Scheme 6

Scheme 7

Scheme 7

Scheme 8

Scheme 8
  1. Normal
  2. One error code
  3. More error codes than two
  4. Checking each error code

DTC CHART

If malfunction code is displayed during the DTC check, check the circuit listed for that code in DTC - TROUBLE DETECTION REFERENCE .

DTC codeDetection itemTrouble area
00Normal
11Open IN-CAR Sensor circuitIn-car sensor Harness or connector between in-car sensor and A/C control assembly A/C control assembly
12Shorted IN-CAR Sensor circuit
13Open Ambient sensor circuitAmbient sensor Harness or connector between ambient sensor and A/C control assembly A/C control assembly
14Shorted Ambient sensor circuit
15Open water Temp. sensorWater temp. sensor Harness or connector between water Temp. sensor and A/C control assembly A/C control assembly
16Shorted water Temp. sensor
17Open thermistorPin thermistor Harness or connector between EVAP. sensor and A/C control assembly A/C control assembly
18Shorted thermistor
19Open or shorted Temp. door potentiometerHarness or connector between Temp. door potentiometer and A/C control assembly
20Defective Temp. door potentiometerTemp. door potentiometer
21Open or shorted mode door potentiometerHarness or connector between mode door potentiometer and A/C control assembly
22Defective mode door potentiometerMode door potentiometer

DTC - TROUBLE DETECTION REFERENCE TABLE

FAIL SAFE FUNCTION

No.ItemFailureFAIL SAFE Function
1IN-CAR temperature sensorOpen/Short25°C alternate value control
2Ambient temperature sensorOpen/Short20°C alternate value control
3Thermistor sensorOpen/Short2°C alternate value control
4Water temperature sensorOpen/Short20°C alternate value control
5Temperature door potentiometerOpen/Short setup temperatureFor 17°C to 24.5°C, set to maximum cooling position. For 25°C to 32°C, set to maximum heating position.
6Mode door potentiometerOpen/Short setup modeVent mode, at vent mode Def mode, at except vent mode

FAIL SAFE FUNCTION

ON-VEHICLE INSPECTION

This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established

TEST CONDITIONS

  1. Temperature at the air inlet with the switch set at RECIRC is 30~35°C (86~95°F)
  2. Engine running at 1,500 RPM
  3. Blower speed control knob on "4" position
  4. Temperature control knob on "COOL" position NOTE: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.

Scheme 9

Scheme 9

Scheme 10

Scheme 10

Scheme 11

Scheme 11

Scheme 12

Scheme 12

Scheme 13

Scheme 13

Scheme 14

Scheme 14

Scheme 15

Scheme 15

Scheme 16

Scheme 16

Scheme 17

Scheme 17
  1. Normally functioning refrigeration system. Gauge reading: Low pressure side: 0.15~0.25 MPa (21.8~36.3 psi, 1.5~2.5 kgf/cm 2 ) High pressure side: 1.37~1.57 MPa (199~228 psi, 14~16 kgf/cm 2 )
  2. Moisture present in refrigeration system. DIAGNOSIS TROUBLESHOOTING - MOISTURE PRESENT IN REFRIGERATION SYSTEM Symptom seen in refrigeration system Probable cause Diagnosis Remedy During operation, pressure on low pressure side sometimes become a vacuum and sometime normal Moisture entered in refrigeration system freezes at expansion valve orifice and temporarily stops cycle, but normal state is restored after a time when the ice melts Drier in oversaturated state Moisture in refrigeration system freezes at expansion valve orifice and block circulation of refrigerant Replace drier Remove moisture in cycle through repeatedly evacuating air Charge proper amount of new refrigerant
  3. Insufficient cooling DIAGNOSIS TROUBLESHOOTING - INSUFFICIENT COOLING Symptom seen in refrigeration system Probable cause Diagnosis Remedy Pressure low on both low and high pressure sides Insufficient cooling performance Gas leakage at some place in refrigeration system Insufficient refrigerant in system Refrigerant leaking Check for gas leakage with gas leak detector and repair if necessary Charge proper amount of refrigerant If indicated pressure value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak
  4. Poor circulation of refrigerant DIAGNOSIS TROUBLESHOOTING - POOR CIRCULATION OF REFRIGERANT Symptom seen in refrigeration system Probable cause Diagnosis Remedy Pressure low in both low and high pressure sides Frost on tube from receiver to unit Refrigerant flow obstructed by dirt in drier Condenser clogged Replace drier
  5. Refrigerant does not circulate DIAGNOSIS TROUBLESHOOTING - REFRIGERANT DOES NOT CIRCULATE Symptom seen in refrigeration system Probable cause Diagnosis Remedy Vacuum indicated on low pressure side, very low pressure indicated on high pressure side Frost or dew seen on piping before and after receiver/driver or expansion valve Refrigerant flow obstructed by moisture or dirt in refrigeration system Refrigerant flow obstructed by gas leakage from expansion valve Refrigerant does not circulate Check expansion valve Clean out dirt in expansion valve by blowing with air Replace drier Evacuate air and charge new refrigerant to proper amount For gas leakage from expansion valve, replace expansion valve
  6. Refrigerant overcharged or insufficient cooling of condenser DIAGNOSIS TROUBLESHOOTING - REFRIGERANT OVERCHARGED OR INSUFFICIENT COOLING OF CONDENSER Symptom seen in refrigeration system Probable cause Diagnosis Remedy Press too high on both low and high pressure sides Unable to develop sufficient performance due to excessive Insufficient cooling of condenser Excessive refrigerant in cycle --> refrigerant overcharged Condenser cooling --> condenser fins clogged or condenser fan faulty Clean condenser Check cooling fan with fluid coupling operation. If (1) and (2) are in normal state, check amount of refrigerant Charge proper amount of refrigerant
  7. Air present in refrigeration system DIAGNOSIS TROUBLESHOOTING - AIR PRESENT IN REFRIGERATION SYSTEM Symptom seen in refrigeration system Probable cause Diagnosis Remedy Press too high on both low and high pressure sides The low pressure piping hot to the touch Air entered in refrigeration system Air present in refrigeration system Insufficient vacuum purging Check compressor oil to see if it is see if it is dirty or insufficient Evacuate air and charge new refrigerant
  8. Expansion valve improperly DIAGNOSIS TROUBLESHOOTING - EXPANSION VALVE IMPROPERLY Symptom seen in refrigeration system Probable cause Diagnosis Remedy Pressure too high on both low and high pressure sides Frost or large amount of dew on piping on low pressure side Trouble in expansion valve Excessive refrigerant in low pressure piping Expansion valve opened too wide Check expansion valve Replace if defective
  9. Defective compression compressor DIAGNOSIS TROUBLESHOOTING - DEFECTIVE COMPRESSION COMPRESSOR Symptom seen in refrigeration system Probable cause Diagnosis Remedy Pressure too high on low high pressure sides Pressure too low to on high pressure side Internal leak in compressor Compression defective Valve leaking or broken sliding parts Repair or replace compressor

INSPECT FOR LEAKAGE OF REFRIGERANT

Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when conducting service operations which are accompanied by disassembly or loosening or connection fittings.

Note. In order to use the leak detector properly, read the manual supplied by the manufacturer.

If a gas leak is detected, proceed as follows

Scheme 18

Scheme 18: INSPECT FOR LEAKAGE OF REFRIGERANT
  1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage with a leak detector.
  2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
  3. Check the compressor oil and add oil if required.
  4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.

PERFORMANCE TEST

The performance test will help determine if the air conditioner system is operating within specifications.

CAUTIONAir conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. Be careful when connecting service equipment. Do not breathe refrigerant or vapor.

If accidental system discharge occurs, ventilate work area before resuming service.

R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air.

WARNINGCompressed air mixed with R-134a forms a combustible vapor. The vapor can burn or explode causing serious injury. Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

Scheme 19

Scheme 19
  1. Connect a R-134a refrigerant recover/recycling/charging station to the high-pressure service port and the low-pressure service port, following the equipment manufacturer's instructions.
  2. Insert a thermometer in the center vent. Determine the relative humidity and air temperature.
  3. Test conditions: Avoid direct sunlight. Open the hood. Open the front doors. Set the temperature control dial on MAX COOL, the mode control switch on VENT and the recirculation control switch on RECIRCULATE. Turn the A/C switch on and the fan switch on MAX. Run the engine at 1,500 RPM. No driver or passengers in vehicle.
  4. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the high and low system pressure from the A/C gauges.

REFRIGERANT RECOVERY

CAUTIONAir conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. Be careful when connecting service equipment. Do not breathe refrigerant or vapor.

If accidental system discharge occurs, ventilate work area before resuming service.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

Scheme 20

Scheme 20
  1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C) (Scheme 19), following the equipment manufacturer's instruction.
  2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging.

SYSTEM EVACUATION

CAUTIONAir conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. Be careful when connecting service equipment. Do not breathe refrigerant or vapor.

If accidental system discharge occurs, ventilate work area before resuming service.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

Scheme 21

Scheme 21
  1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using a R-134a refrigerant recover/recycling/charging station (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)
  2. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C) (Scheme 20), following the equipment manufacturer's instruction. Evacuate the system.
  3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks.

SYSTEM CHARGING

CAUTIONAir conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. Be careful when connecting service equipment. Do not breathe refrigerant or vapor.

If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

Scheme 22

Scheme 22
  1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C) (Scheme 21), following the equipment manufacturer's instruction. Evacuate the systems.
  2. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only FD46XG (PAG) refrigerant oil.
  3. Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the compressor will be damaged. Refrigerant capacity: 600 +/- 25g

Scheme 23

Scheme 23: REFRIGERATION CYCLE

Scheme 24

Scheme 24: REPLACEMENT

Scheme 25

Scheme 25

Scheme 26

Scheme 26
  1. After opening the glove box, pull it downward by pressing the both sides of glove box inward
  2. After turning the knob of filter cover counter clock wise, remove the filter cover
  3. Remove the air conditioner upper filter by pulling it horizontally in ward (Scheme 25)
  4. Remove the lower filter by pulling it horizontally inward after lifting
  5. Reinstall all removed components in reverse order of the removal NOTE: When you replace the filters, be sure to align grooves with lugs in the upper and lower filters for correct installation Be sure to pull and push the filters horizontally to remove and install the filters

Scheme 27

Scheme 27: COMPONENT LOCATION

Scheme 28

Scheme 28: COMPONENTS

REMOVAL AND INSTALLATION

  1. Remove the drive belt after loosening the tension pulley.
  2. Discharge the refrigerant.
  3. Remove the discharge and suction hoses.
  4. Remove the compressor.
  5. Installation is the reverse of removal.

Scheme 29

Scheme 29: DISASSEMBLY
  1. Remove the clutch hub supporting bolt using the Special Tool.
  2. Pull out the clutch hub and shim from the compressor shaft. If it is hard to pull out the hub from compressor, insert an 8mm bolt into the shaft hole to remove the hub from the shaft.
  3. Remove the pulley supporting the snap ring.
  4. Remove the pulley and bearing assembly from the compressor.

ASSEMBLY

  1. Clean the pulley bearing surface of the compressor head and remove dirt and rust.
  2. Install the pulley and bearing on the compressor.
  3. Install the snap ring with its bevelled side facing out.
  4. Place one space shim of specified size over the hub spline and slide the hub onto the compressor shaft end.
  5. Install a new hub supporting bolt at the compressor shaft end. Tighten the bolt with tightening torque. Tightening torque: 102 ~ 153 kg.cm CAUTION: Do not use air tools.

Scheme 30

Scheme 30: DISASSEMBLY

Scheme 31

Scheme 31
  1. Remove the clutch hub and pulley.
  2. Install a shaft protection tool at the compressor opening.
  3. Install the pulley on the compressor. Place the puller screw end on the shaft arms center concave and the puller projection around the rear side of the field coil.
  4. Turn the puller screw using a wrench and remove the coil. CAUTION: Do not use air tools.

Scheme 32

Scheme 32: THERMAL FUSE
  1. A thermal fuse is located on the compressor clutch coil.
  2. The thermal fuse will detect clutch slip heat (184°C off) generated by faulty compressor operation, then interrupt the coil's power supply. Therefore, the clutch bearing and the pulley bearing will not be damaged, also protecting the belt and engine. Once the thermal fuse blows the compressor will not operate. Check the clutch oil resistance (3.0~3.2ohms) to determine the thermal fuse condition, and replace the clutch coil if required.

Scheme 33

Scheme 33: CHECKING THE CLUTCH AIR GAP
  1. Check the air gap between the clutch hub and pulley contact surface using a feeler gauge. Clutch air gap: 0.35~0.65 mm
  2. Check the gap around the pulley at 3 points.
  3. If the clutch air gap is outside the normal range, correct it using a shim of proper size.

MAGNETIC CLUTCH OPERATION

Connect the compressor terminal to battery (+) and the battery (-) terminal to the compressor body. Verify magnetic clutch operation by a clicking noise.

Scheme 34

Scheme 34: MAGNETIC CLUTCH OPERATION

Scheme 35

Scheme 35: COMPONENTS

CONDENSER

  1. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with compressed air. If bent, gently bend them using a screwdriver or a pliers.
  2. Check the condenser connections for leakage, and repair or replace it, if required.

Scheme 36

Scheme 36: CONDENSER FAN
  1. Check the condenser fan for proper operation.
  2. Check the harness connector.
  3. Check the condenser fan motor using battery voltage (Scheme 36)

Scheme 37

Scheme 37: INSPECTION
  1. Check the fusible plug and the fittings for leakage, using a leak detector.
  2. Run the engine at fast idle with the air conditioning "ON" and check both the inlet and outlet temperatures. If the difference in temperatures between the inlet and outlet is large, replace the receiver/drier. NOTE: Plug all the open fittings immediately to keep moisture out of the system. Do not remove plugs until ready for connection. If the receiver/drier is replaced with a new unit, add 40cc of compressor oil to the compressor. Evacuate, charge and test the refrigeration system.

Scheme 38

Scheme 38: REPLACEMENT
  1. Remove the condenser, and then remove the bottom cap (B) from the receiver/drier tank (A). WARNING: Use of impact wrench may cause cracking on the receiver/drier tank connecting pipe to the condenser.
  2. Remove the desiccant from the receiver/drier tank using a long nose plier.
  3. Check for crumbled desiccant and clogged bottom cap filter.
  4. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
  5. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed to air for use.
  6. Install the new bottom cap to the receiver drier tank. Tightening torque: 20~32 Nm (200-250 kgf.cm, 14.5~18.2 lbf.ft) NOTE: Always replace the desiccant and bottom cap at the same time.

DESCRIPTION

The triple switch is a combination of a medium switch as well as conventional low pressure and high pressure switches. The low pressure switch will be turned off to stop compressor operation if refrigerant pressure is low. The high pressure switch will be turned off to stop compressor operation if refrigerant pressure is too high. The medium switch will be turned on at medium level pressure to cool the A/C system operating radiator fan and condenser fan at high speed.

OPERATING CHARACTERISTIC (kg/cm 2 )

PressureONOFF
High32.0 +/- 2.026.0 +/- 2.0
Low2.3 +0.25 -0.292.0 +/- 0.2
Medium18.0 +/-0.814.0 +/-1.2

PRESSURE SPECIFICATIONS

LOW & HIGH

Scheme 39

Scheme 39

MEDIUM

Scheme 40

Scheme 40

Scheme 41

Scheme 41: CONNECTOR

Scheme 42

Scheme 42: CIRCUIT DIAGRAM

The photo sensor is located by the driver side defrost nozzle. In response to photo intensity level in vehicle, the sensor will send signal to control module to control the blower level and discharge temperature.

Scheme 43

Scheme 43: DESCRIPTION

Note. Emit intensive light toward driver side and passenger side using a lamp, and check the current change between terminals 1 & 2.

Scheme 44

Scheme 44
  1. The AQS , located at the center support in front of the center member, detects hazardous elements in ambient air, and provides output signals to the control module.
  2. It will detect sulfurous acid gas, carbon dioxide, carbon monoxide, hydrocarbon and allergen.

SENSOR OUTPUT

ConditionResistance
Normal condition5V
Hazardous gas detection0V

SENSOR OUTPUT RESISTANCE SPECIFICATIONS

Scheme 45

Scheme 45: CONNECTOR

Scheme 46

Scheme 46: CHECKING METHOD OF GAS DETECTING BENCH
  1. Put the sensor part of AQS toward the air inflow (intake) direction.
  2. Connect all of the power supply line and output line to AQS.
  3. Close the chamber LID after putting the lines in order.
  4. Connect the air outlet part of vacuum pump with the air inlet door of chamber by using air hose.
  5. Turn on the power of vacuum pump.
  6. Supply the power to the AQS (DC 12V).
  7. LED of AQS is kept "ON" for the first 35 +/- 2 seconds after supplying the power.
  8. Wait until all of the LEDs are "OFF". Put the diesel engine exhaust gas into the chamber. Then check the LEDs of number 1 to 10 are "ON".
  9. After check LEDs are "ON". Put the clean air into the chamber. Then check LEDs are "OFF".
  10. Wait until all of the LEDs are "OFF".
  11. And then put the gasoline engine exhaust gas into the chamber, then check the LEDs of number 1 to 10 are "ON".
  12. After check LEDs are "ON". Put the clean air into the chamber. Then check LEDs are "OFF".

Scheme 47

Scheme 47: DESCRIPTION
  1. The air temperature sensor, located at the front of the engine radiator, and detect ambient air temperature. It is a negative type thermistor; resistance will increase with lower temperature, and decrease with higher temperatures.
  2. The sensor output will be used for discharge temperature sensor, sensor fail-safe, temperature regulation door control, blower motor level control, mix mode control and in-car humidity control.

CHECK

Temperature (°C)Min. Resistance (ohms)Max. Resistance (ohms)
40787.25982.15
20254.8287.5
089.2109.6
2035.039.5
4015.117.1
607.18.0

AMBIENT TEMPERATURE SENSOR RESISTANCE SPECIFICATIONS

Scheme 48

Scheme 48

It will detect interior temperature, which will be used for discharge temperature control, sensor fail-safe, temperature door control, blower motor level control, A/C auto control.

Scheme 49

Scheme 49: DESCRIPTION

Scheme 50

Scheme 50: COMPONENTS

Scheme 51

Scheme 51: COMPONENTS

Scheme 52

Scheme 52

Scheme 53

Scheme 53: TEMPERATURE CONTROL ACTUATOR
  1. Temperature control actuators are installed in the heater unit case. The control switches and the vent duct switch will operate actuators to regulate the temperature and discharge air.
  2. Temp. switch terminal voltage check. TEMP. SWITCH TERMINAL VOLTAGE Terminal Voltage Remark 1 12V (+, -) Change Polarity 3 12V (+, -) Change Polarity 4 5V Sensor Voltage 5 Change with resistance Variable Resistance 6 Ground Ground

Scheme 54

Scheme 54: MODE CONTROL ACTUATOR
  1. Pressing the mode select switch with the ignition on will shift the driver side and passenger side mode door actuators as follows: VENT => BI/LEVEL => FLOOR => MIX
  2. Mode actuator circuit diagram and voltage. MODE CONTROL ACTUATOR TERMINAL VOLTAGE Terminal Description Voltage 1 IG 12V 2 Ground - 3 Vent 0V 4 Bi-level 12V 5 Floor 12V 6 Mix 12V 7 Defroster 12V

RATE OF FLOW DISTRIBUTION (%)

Scheme 55

Scheme 55

Scheme 56

Scheme 56: COMPONENTS

Scheme 57

Scheme 57

Scheme 58

Scheme 58: REMOVAL

Scheme 59

Scheme 59

Scheme 60

Scheme 60

Scheme 61

Scheme 61

Scheme 62

Scheme 62
  1. After opening the glove box, pull it downward by pressing the both side of glove box inward.
  2. Remove the lower side cover of the crash pad.
  3. Remove the upper cover of the glove box.
  4. Loosen the bolts of glove box.
  5. Remove the evaporator and blower mounting bolts.
  6. Remove the blower motor.

THERMISTOR

The thermistor will detect the core temperature and interrupt compressor relay power, in order to prevent evaporator freezing by excessive cooling.

Scheme 63

Scheme 63: THERMISTOR
  1. Thermistor check Remove the glove box. Start the engine. Turn on the air conditioner. Using the multi-tester, check the output voltage between terminals 2 and 3 in the thermistor. THERMISTOR OUTPUT VOLTAGE SPECIFICATIONS Thermistor Operating temperature Output voltage ON 0.5 +/- 0.5°C 12V OFF 2.5 +/- 0.5°C 0V

Scheme 64

Scheme 64: WATER TEMPERATURE SENSOR
  1. The water temperature sensor, located at the heater core, detects coolant temperature flowing through heater core. It is a negative type thermistor; resistance will increase with lower temperatures, and decrease with higher temperatures.
  2. The sensor will compare temperature settings with the IN-CAR air temperature or the ambient air temperature for motive heating control. CHECK WATER TEMPERATURE SENSOR RESISTANCE SPECIFICATIONS Water temperature Resistance 25°C 10Kohms 60°C 2.50Kohms
  3. Electromotive heating control At AUTO mode, discharge mode FLOOR or B/L, if coolant temperature is low, it will perform motive heating control to prevent cold air discharge toward the passenger legs. Operation control Discharge mode FLOOR or B/L at AUTO control Coolant temperature is low System operation Mode door: DEF => MIX => AUTO Blower level: AUTO LO => AUTO HI Intake door: Ambient air

FRESH AIR RECIRCULATION SWITCHING ACTUATOR

The intake selection switch is located on the control panel. Pressing the switch will shift between recirculation and fresh air modes.

Scheme 65

Scheme 65: FRESH AIR RECIRCULATION SWITCHING ACTUATOR

CHECK

InputOutput
12Fresh/recirculation shifting
+Recirculation
+Fresh

FRESH AIR RECIRCULATION SWITCHING ACTUATOR INSPECTION

INSTALLATION

Installation is the reverse of removal.

INSPECTION

Apply the battery voltage as shown and check the blower motor rotation.

Scheme 66

Scheme 66: INSPECTION

Scheme 67

Scheme 67: INSPECTION
  1. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2.
  2. Select the control switch to raise voltage until high relay operates POWER TRANSISTOR SPECIFICATIONS Fan Motor Voltage First speed 3.8V +/- 0.5V Second speed 5.2V +/- 0.5V Third speed 6.5V +/- 0.5V Fourth speed 7.9V +/- 0.5V Fifth speed 9.5V +/- 0.5V Sixth speed 10.6V +/- 0.5V Seventh speed 12.0V (high relay operates)

Scheme 68

Scheme 68: REPLACEMENT

Scheme 69

Scheme 69

Scheme 70

Scheme 70

Scheme 71

Scheme 71

Scheme 72

Scheme 72
  1. Remove the negative (-) battery terminal
  2. After opening the glove box, pull it downward by pressing the both side of glove box inward
  3. Remove the lower side cover of the crash pad.
  4. Remove the upper cover of the glove box.
  5. Loosen the bolts of glove box.
  6. Disconnect the power transistor connector (A).
  7. Loosen the power transistor fixing screw and remove the power transistor CAUTION: Use the short length positive (+) screwdriver to remove the screw.
  8. Replace the power transistor with a new one.
  9. Reinstallation is the reverse order of the removal.

Scheme 73

Scheme 73: INSPECTION

Scheme 74

Scheme 74
  1. Measure terminal-to-terminal resistance of the blower resistor.
  2. If measured resistance is not within specification, the blower resistor must be replaced. (After removing the resistor).

Scheme 75

Scheme 75: REPLACEMENT

Scheme 76

Scheme 76

Scheme 77

Scheme 77

Scheme 78

Scheme 78

Scheme 79

Scheme 79
  1. Remove the negative (-) battery.
  2. After opening the glove box, pull it downward by pressing the both side of glove box inward.
  3. Remove the lower side cover of the crash pad.
  4. Remove the upper cover of the glove box.
  5. Loosen the bolts of glove box.
  6. Disconnect the blower heater resistor connector (A).
  7. Loosen the resistor fixing screw and remove the resistor. CAUTION: Use the short length positive (+) screwdriver to remove the screw.
  8. Replace the resistor with a new one.
  9. Reinstallation is the reverse order of the removal.

Scheme 80

Scheme 80: REPLACEMENT

Scheme 81

Scheme 81

Scheme 82

Scheme 82
  1. After opening the glove box, pull it downward by pressing both sides of the glove box inward.
  2. After turning the knob of the filter cover counter clockwise, remove the filter cover.
  3. Remove the air conditioner upper filter by pulling it horizontally in ward as shown.
  4. Remove the lower filter by pulling it horizontally inward after lifting.
  5. Reinstall all removed components in reverse order of the removal

Note. When you replace the filters, be sure to align the grooves with lugs in the upper and lower filters for correct installation. Be sure to pull and push the filters horizontally to remove and install the filters

SCHEMATIC DIAGRAM

For blower and A/C controls (manual) schematic diagrams, see AIR CONDITIONING Wiring Diagrams article .

Scheme 83

Scheme 83: COMPONENTS
FUNCTIONDISPLAYFUNCTION ( SYSTEM STATE DESCRIPTION)REMARKS
SWITCHMODETEMPFRERECA/CMODETEMPFRE/RECA/CBLOWER
All flow control modeMax A/CVENTOFFONONVENTRECONONSee 4 )
VENTVENTVENTON
B/LB/LB/LON
OFFOFFONOFFOFFDEFFREOFFOFFSee 3 )
FLOORFLOORONOFFFLOORFREONSee 2 )
MIXMIXONOFFONMIXFREONONSee 1 , 2
Temperature controlDEFDEFONOFFONDEFFREONONSee 1 , 2
WARMWARMWARM
Air intake controlCOOLCOOLCOOL
FREONOFFFRE
Air conditionerRECOFFONREC
ONONON
OFFOFFOFF

CONTROL PANEL DISPLAY FUNCTION

Note. VENT: Ventilation (FACE mode) B/L: Bi-Level (FACE-FLOOR mode) MIX: DEFROST-FLOOR mode DEF: DEFROST mode FRE: FRESH air mode REC: RECIRCULATION mode

  1. A/C operation logic (Defogging logic) When MIX or DEF mode is selected, the air conditioning system is switched ON. Compressor signal ON at all time. A/C indicator remains the state before entering this logic. When MIX or DEF mode is selected, A/C cannot be turned OFF. Only A/C indicator can be turned ON and OFF when pressed. A/C indicator is not turned ON at MIX or DEF mode although A/C is operating if A/C was not used before selecting MIX or DEF mode. When the directional mode control is switch to the other mode from MIX or DEF mode, the A/C indicator is returned to the state before entering this logic.
  2. Air intake control operation logic (Defogging logic) When FLOOR or MIX or DEF mode is selected, the air intake control switches to fresh air. Fresh air or recirculation mode can be selected. Once the fresh air or recirculation mode is selected in this logic, this defogging logic is cancelled. When air intake control mode is switched to the other mode from FLOOR or MIX or DEF mode, air intake control mode returns to the state before selecting the logic. When an air flow direction within FLOOR <=> MIX <=> DEF mode is reselected, air intake control logic operates again.
  3. Air control mode OFF logic At the state of mode OFF, the blower (and A/C switch) does not operate and the air flow control mode is set to DEF mode and the air intake control mode is set to fresh air mode. However, recirculation or fresh air mode can be selected. When mode OFF is cancelled, fresh air mode is selected and A/C is returned to the state before selecting mode OFF.
  4. Max. A/C logic When Max. A/C mode is selected, VENT mode A/C ON Intake REC. A/C OFF and FRE can not be selected.

IN CASE OF IGNITION ON/OFF

IGNITION SWITCHFRE/RECA/CREMARKS
ONFREMEMORIZED MODEWhen selecting MIX or DEF mode, MIX or DEF logic operates again.
OFFFRE

IN CASE OF IGNITION ON/OFF CHART

  1. Fresh air mode operates for 10 +/- 1 seconds after turning the ignition off.
  2. However, all display remains OFF.

Scheme 84

Scheme 84: CONNECTOR CONFIGURATION
USEPINNAMEUSEPINNAME
AMAIN S/W1GNDAMAIN S/W16FLOOR
2S/GND17MIX
3BAT.18DEF
4IGN19
5ILL +20
6ILL21BLR RELAY (-)
7WARM22
8COOL23A/C OUTPUT
9TEMP F/BACKBBLOWER S/W1LOW
10VCC2MIDDLE LOW
11FRE3HIGH
12REC4GND
135
14VENT6MIDDLE HIGH
15B/L

CONNECTOR PIN NAME

Scheme 85

Scheme 85: SCHEMATIC DIAGRAM

Scheme 86

Scheme 86: CIRCUIT DIAGRAM

For blower and A/C controls (automatic) schematic diagram, see AIR CONDITIONING Wiring Diagrams article .

Scheme 87

Scheme 87: COMPONENTS
  1. Full auto air conditioning system: One-touch button type.
  2. Manual air conditioning system: Combination of dial switch and one-touch button.

CONTROL PANEL SWITCHES WILL GENERATE BUZZER SOUND ON OPERATION

ButtonFunctionDisplaySystem operationStop switch and system operation
Temperature switch (Temperature control) (Manual air conditioning systems have dial type switches)Temperature setting UP/DOWNTemperature setting indication Range: 17°C~32°C Scale: 0.5°C User may chose the temperature indication between °C/°F. 17°C = 62°F 32°C = 90°F 25°C = 77°FThe switch will operate temperature door to regulate cool/warm air ratio and resultingly control discharge air control. The switch will raise up or lower down the temperature by unit of 0.5. Setting at 17°C (62°F) will provide max. cooling, and setting at 32°C (90°F) will provide max. heating. Switching off --> on, it will display the temperature setting just before the previous switching-off. In shifting 17.5°C --> 17°C or 31.5°C --> 32°C, raising temperature setting will generate buzzer sound 5 times at interval of 0.15 seconds. Lowering temperature setting at 17°C or raising temperature setting at 32°C, it will generate buzzer sound 5 times at interval of 0.15 sec. Pressing repeatedly on: Shift one unit every 0.7 second. Holding down: First shift in 0.7 seconds and than shift every 0.3 seconds (buzzer sound for 0.1 second upon each shift)Turning off the switch, the system will be off. Control temperature setting up/down.
AUTO (Auto control)Auto control of air conditioning system"AUTO" will be displayed on control panel.The system will provide auto control of the below features on the basis of temperature setting: Temperature door Mode door Intake door (Shift between fresh air/recirculation) Blower speed Compressor "AUTO" will disappear upon releasing AUTO switch. Features except manually selected switches will be controlled automatically upon releasing auto switch.Off --> system off Blower switch: Manually control blower MODE: Manually control discharge mode A/C: Manually control compressor on/off Fresh air: Manually control fresh air Recirculation: Manually control recirculation Defroster: Manually control defroster (when air conditioning system is on and recirculation selected)
AMBIndicate ambient air temperature'AMB' lamp will come on indicate ambient air temperature other lamps will go out.Pressing AMB switch, any previous indication will go out and 'AMB' lamp and ambient air temperature will come on 5 seconds, and then it will return to the previous indication just before pressing AMB switch.AMB: Pressing the AMB switch when ambient air temperature is indicated, ambient air temperature indication will extinguish. Other switches: Pressing another switch when the ambient air temperature is indicated, ambient air temperature indication will extinguish and selected switch control will be performed.
INTAKERecirculationRecirculation lamp will come on. "AUTO" lamp will go out.Fix intake door at the circulation position.Selecting fresh air at the current condition: Fresh air control off switch Fixing at the current condition (Fresh air selection is possible)- IND lamp will come in. AUTO-auto control (fresh air, recirculation).
Fresh airFresh air lamp will come on. "AUTO" lamp will go out.Fix intake door at the fresh air position.Selecting fresh air at the current condition: Fresh air control off switch Fixing at the current condition (Fresh air selection is possible)- IND lamp will come in. AUTO-auto control (fresh air, recirculation).
Blower fan speed UP/DOWNBlower fan speed, UP/DOWN controlIndicates fan operation on/offPressing fan UP/DOWN switches during auto control, the speed will shift up/down based on the current fan level. Switching on a switch except fan switch at 'off" condition, the speed will rise steadily from LOW to the target speed. (Require 6 seconds from LOW to HI). Shifting a step will take 0.7 seconds when pressing the switch once. Holding on the switch, a shift will occur every 0.3 seconds and buzzer sounds for 0.1 second. Pressing UP switch at HI position or DOWN switch at LOW position, buzzer sound will occur 5 times at 0.15 second interval.AUTO: Auto control OFF: System off Fan speed control: Manually control blower fan speed.
Output increment step by step
Fan speed levels and voltages Auto cooling: No level (4.5V ~ B+) Auto heating: No level (4.5V ~ B+) Manual control: 7 levels (3.8V ~ B+)
A/C Air conditioning switchCompressor on/off controlA/C lamp (on/off) AUTO lamp offAir conditioning on/offA/C: A/C on/off, manual control OFF: System off AUTO: Auto control DEF: Defroster, manual control
MODE (Discharge mode)Mode door control VENT, FLOOR, B/L, MIXMODE indication (on/off) AUTO lamp offFix mode door at B/L or MIX Manual operating mode switch, the switch will shift in the order of VENT-B/L-FLOOR-MIXMODE: Shift control in order of Vent-B/L-Floor-Mix-Vent DEF: Defroster, manual control AUTO: Auto control
DEF (Defroster) Remove moisture/frost on windshield.DEF controlDEF IND on DEF indication on A/C lamp on INTAKE IND off AUTO lamp offMode door: Fixed at defroster. Intake door: Fresh air control (Selecting recirculation is enabled). A/C: on (Compressor will be controlled on/off based on detected temperature by fin sensor). Prevails over max. cooling and max. heating. Prevails over mix mode controlAUTO: System auto control MODE: Discharge mode, manual control (release the defroster control) A/C: A/C on/off, manual control DEF: Return to the previous condition before selecting DEF switch
OFFSystem offControl panel LCD offBlower fan speed off. Air conditioning off. Intake door: Fixed at the location prior to system off. Temperature door: Auto control. Mode door: Fixed at the condition prior to system off. AMB Pressing AMB switch after system off, 'AMB' lamp/ambient air temperature will come on for 5 seconds and then go out.AUTO: Auto control Blower speed: Return to MANUAL LOW Others: Return to the previous condition before system off
A/C: Air conditioning on Others: Return to the previous condition before system off (Blower speed: Return to MANUAL LOW)
INTAKE (recirc/fresh air) control at the system off condition Selecting the fresh air switch at the recirculation position after system off: It will shift to the fresh air position and extinguish the recirculation indicator lamp. The LCD will be held off. Selecting the recirculation switch at the fresh air position after system off: It will shift to the recirculation position and extinguish the recirculation indicator lamp. The LCD will be held off. Other switches will be held off at the above condition.MODE: Held at the previous condition before system off. (Auto control is released). Others: Return to the previous condition before system off (Blower speed: Return to MANUAL LOW)
DEF: Shift to defroster mode Air conditioning on/Intake (fresh air) Others: Return to the previous condition before system off
TEMP: Held at the previous condition before system off Others: Return to the previous condition before system off
DEFOGRear glass defogger onDefogger switch indicator on/offPressing DEFOG switch, the switch signal will be sent to ETACS. Pressing the switch again, defogging will stop and the indicator will go out. Released by ETACS after 15 minutes of control.Pressing DEFOG switch again, it will be released.

CONTROL PANEL SWITCHES WILL GENERATE BUZZER SOUND ON OPERATION CHART

Scheme 88

Scheme 88: CONNECTOR CONFIGURATIONS
USEPINNAMEREMARKUSEPINNAMEREMARK
AFATC COMPONENT1RHEOSTATBFATC COMPONENT1IN-CAR SENSOR IN
2TAIL LAMP2A/C SELECT
3BATTERY3AMB. SENSOR (+)
4POWER TR (B)4EVA. SENSOR (+)
5POWER TR (C)5
6TEMP ACT (CCW)COOL6
7INTAKE ACT (CCW)REC7AQS
88SENSOR REF (+5V)
9IG29IN-CAR SENSOR OUT
10GND10TEMP F/B SIGNAL
11A/CON OUTPUT11VENT
12HI SPEED RELAY12B/L
13PHOTO SENSOR (+)13FLOOR
14PHOTO SENSOR GND14MIX
1515DEF
16TEMP ACT (CW)WARM16SENSOR GND
17INTAKE ACT (CW)FRESH
18
19IG2
20GND

CONNECTOR CONFIGURATIONS CHART

Scheme 89

Scheme 89: CIRCUIT DIAGRAM