Air Conditioning System Hyundai Santa Fe III

When Handling Refrigerant

1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When handling the refrigerant, be sure to wear gloves.
2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If refrigerant splashes into your eyes, wash them with clean water immediately.
3. The R-134a container is highly pressurized. Never leave it in a hot place, and check if storage temperature is below 52°C (126°F)
4. An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-134a, upon coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended lubricant for R-134a systems. If lubricants other than the recommended one used, system failure may occur.
6. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be observed: When removing refrigerant components from a vehicle, cap the components immediately to prevent entry of moisture. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the components. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from taking on moisture. Use the recommended lubricant from a sealed container only.
7. If an accidental discharge in the system occurs, ventilate the work area before resume of service.

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When Replacing Parts on A/C System

1. Never open or loosen a connection before discharging the system.
2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
3. Do not remove the sealing caps from a replacement component until it is ready to be installed.
4. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil before making the connection.

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Flange With Guide Pin

Check the new O-ring for damage (use only the specified) and lubricate by using compressor oil. Tighten the nut to the specified torque.

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Handling Tubing and Fittings

The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and cause problems or serious damage.

The Following Precautions Must Be Observed

1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready so the system will not be left open any longer than necessary.
2. Cap or plug all lines and fittings as soon as they are opened to prevent entrance of dirt and moisture.
3. All lines and components in parts stock should be capped or sealed until they are ready to be used.
4. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including refrigerant dispensing manifold, gauge set manifold and test hoses, should be kept clean and dry.

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Refrigerant Recovery

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a) from the air conditioning system.

If accidental system discharge occurs, ventilate the work area before resume of service.

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

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1. Connect a R-134a refrigerant Recovery/Recycling/Charging system (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to install the same amount of new refrigerant oil back into the A/C system before charging.

System Evacuation

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a) from the air conditioning system.

If accidental system discharge occurs, ventilate the work area before resume of service.

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

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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 Recovery/Recycling/Charging system. (If the system has been open for several days, the receiver/drier should be replaced, and the system should be evacuated for several hours.)
2. Connect a R-134a refrigerant Recovery/Recycling/Charging system (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks (see «REFRIGERANT LEAK TEST»(/hyundai/santa-fe/iii-2012-2016/remont/automatic-hvac-system/#air-conditioning-system__refrigerant-leak-test) .)
4. Remove the low pressure valve from the low-pressure service port.

System Charging

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a) from the air conditioning system.

If accidental system discharge occurs, ventilate the work area before resume of service.

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

Scheme 9

1. Connect a R-134a refrigerant Recovery/Recycling/Charging system (A) to the high-pressure service port (B) as shown, following the equipment manufacturer's instructions.
2. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only specified refrigerant oil. Charge the system with [Front only: 600±25g (21.1±0.88oz.), Front&Rear: 800±25g (28.2±0.88oz.)] R-134a refrigerant. Do not overcharge the system the compressor will be damaged.

Refrigerant Leak Test

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

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 (A).
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.

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Oil Specification

1. The HFC-134a system requires synthetic (PAG) compressor oil whereas the R-12 system requires mineral compressor oil. The two oils must never be mixed.
2. Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of compressor.

Handling of Oil

1. The oil should be free from moisture, dust, metal powder, etc.
2. Do not mix with other oil.
3. The water content in the oil increases when exposed to air. After use, seal oil from air immediately. (HFC-134a Compressor Oil absorbs moisture very easily.)
4. The compressor oil must be stored in steel containers, not in plastic containers.

Compressor Oil Check

The oil used to lubricate the compressor circulates with the refrigerant.

Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil.

Oil total volume in system

Front only: PAG 120 ± 10cc (4.1±0.3oz.)

Front&Rear: PAG 210 ± 10cc (7.1±0.3oz.)

Oil Return Operation

There is close affinity between the oil and refrigerant.

During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of oil in the system, or replacing any component of the system, the compressor must run in advance for oil return operation. The procedure is as follows

1. Open all the doors and engine hood.
2. Start the engine and air conditioning switch to "ON" and set the blower motor control knob at its highest position.
3. Run the compressor for more than 20 minutes between 800 and 1, 000 RPM in order to operate the system.
4. Stop the engine.

Replacement

1. Discharge refrigerant from the refrigeration system.
2. Replace faulty tube or hose. CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system.
3. Tighten the bolt or nut joint to the specified torque. CAUTION: Connections should not be torque tighter than the specified torque.
4. Evacuate air in the refrigeration system and charge system with refrigerant. Specified amount Front only: 600 ± 25 g (21.1 ± 0.88 oz.) Front&Rear: 800 ± 25 g (28.2 ± 0.88 oz.)
5. Inspect for leakage of refrigerant. Using a gas leak detector, check for refrigerant leakage.
6. Inspect A/C operation.

Description

The compressor is the power unit of the A/C system.

It is located on the side of engine block and driven by a V-belt of the engine.

The compressor changes low pressure and low temperature refrigerant gas into high pressure and high temperature refrigerant gas.

Variable Swash Plate Compressor

The compressor has a swash plate that rotates to reciprocate pistons, which compress refrigerant.

The variable swash plate compressor controls the swash plate angle to change the refrigerant displacement. It achieves precise cooling capability control in accordance with vehicle interior and driving conditions.

The internally controlled variable swash plate compressor changes the swash plate angle by a MCV (Mechanical Control Valve) in accordance with fluctuation of a suction pressure.

The externally controlled variable swash plate compressor changes the swash plate angle by an ECV (Electric Control Valve) in accordance with an electrical signal from the heater & A/C control unit.

This enables stable temperature control and improved driving sensation.

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1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.
2. Disconnect the negative (-) battery terminal.
3. Recover the refrigerant with a recovery/charging station.
4. Remove the engine room under cover by loosening the mounting clip (A) and bolts (B).
5. Separate the front portion of the front wheel guard from the wheel base. (Refer to " «FRONT WHEEL GUARD»(/hyundai/santa-fe/iii-2012-2016/remont/exteriorinterior-trim/#body-side-molding) ")
6. Remove the engine room right side under cover.
7. Loosen the drive belt. (Refer to " «DRIVE BELT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#timing-system) ")
8. Remove the bolts, then disconnect the suction line and discharge line from the compressor. NOTE: Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
9. Disconnect the compressor switch connector (A).
10. Remove the compressor by loosening the mounting bolts.

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1. Make sure the compressor mounting bolt with the correct length is screwed in. Tighten the mounting bolts with the specified tightening order. Tightening torque: 20.00~32.95 N.m(2.04 ~ 3.36 kgf.m, 14.75~24.30 lb-ft)
2. Install in the reverse order of removal. If you install a new compressor, drain all the refrigerant oil from the removed compressor and measure its volume. Subtract the volume of drained oil from the original capacity. The result is the amount of oil compressor oil you should drain from the new compressor (through the suction fitting). Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.

Inspection

1. Check the plated parts of the limiter & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the assembly.
2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the pulley with a new one if it is noisy or has excessive play/drag.

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External Control Valve Compressor Inspection (GDS)

Compressor type: Fixed type compressor, External control valve, Internal control valve.

In cases of fixed type and internal control valve, it is possible to inspect compressor's operation with clutch noise.

When it comes to External control valve, however, it cannot be checked in this way because it doesn't have a clutch.

So, ECV should be inspected with GDS as below.

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1. Connect GDS to the vehicle and select 'Aircon Compressor Test (ECV type)' [ECV1]
2. Make the vehicle ready as the GDS instruction on the monitor. (Turn off A/C 'switch' only) [ECV2] [ECV3]
3. Check if other DTC codes are found before inspect ECV compressor. If so, solve that problems first. If not, press 'OK' button to continue. Information Do not continue inspection if these DTC codes are found: B1241, B1242, B1672, B1685, B1686, B1687 [ECV4]
4. Start inspection [ECV5] [ECV6] CAUTION: if condenser fan is operating when condition is changed to 'ECV running' CAUTION: Relief valve will be operated if a condenser fan doesn't work because of overpressure in the compressor. It helps the air-conditioning system to relieve by releasing refrigerant and oil. (Closed if relieved) Refill refrigerant and oil after operation of Relief valve Noise occurred when Relief valve is in operation
5. Check the result of inspection and click 'Check Detail' if it's 'Check'. Follow the instruction and inspect ECV again from the first step. [ECV7] [ECV8]

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1. Remove the engine room under cover by loosening the mounting clip (A) and bolts (B).
2. Separate the front portion of the front wheel guard from the wheel base. (Refer to " «FRONT WHEEL GUARD»(/hyundai/santa-fe/iii-2012-2016/remont/exteriorinterior-trim/#body-side-molding) ")
3. Remove the engine room right side under cover.
4. Loosen the drive belt. (Refer to " «DRIVE BELT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#timing-system) ")
5. Remove the clutch bolt (A) while holding the pulley with a clutch bolt remover (09977-3R000). Tightening torque: 10.0 ~ 15.0 N.m (1.02 ~ 1.53 kgf.m, 7.37 ~ 11.0 lb-ft)
6. Loosen the limiter bolts and then remove the limiter & hub assembly.
7. Remove the pulley (B) after removing the snap ring (A) with a snap ring plier. NOTE: Be careful not to damage the pulley and compressor during disassembly/reassembly. Once the snap ring is removed, replace it with a new one.
8. Reassemble in the reverse order of disassembly. NOTE: Clean the pulley and compressor sliding surfaces with non-petroleum solvent. Install a new snap ring, and make sure they are fully seated in the groove. Make sure that the pulley turns smoothly after reassembly.

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 pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.

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1. Recover the refrigerant with a recovery/recycling/charging station.
2. Disconnect the negative (-) battery terminal.
3. Remove the front bumper. (Refer to " «FRONT BUMPER COVER»(/hyundai/santa-fe/iii-2012-2016/remont/exterior-body-panels/#front-bumper-grille) ")
4. Remove the 2 nuts, and then disconnect the discharge line and liquid line (A) from the condenser.
5. Remove the intake shield (A).
6. Remove the side air guard (A).
7. Remove the condenser (A) from radiator.
8. Install in the reverse order of removal. NOTE: If you're installing a new condenser, add refrigerant oil. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage. Be careful not to damage the radiator and condenser fins when installing the condenser. Charge the system, and test its performance.

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1. Remove the condenser.
2. Remove the cover (A).
3. Remove the cap (B) on the bottom of the condenser with a L wrench (A). Tightening torque: 9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)
4. Remove the receiver-drier (A) from condenser using a long nose plier. Check for crumbled receiver-drier and clogged bottom cap filter.
5. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
6. Insert a new receiver-drier into the receiver drier tank. The receiver-drier must be sealed in vacuum before it is exposed to air for use.
7. Install a new bottom cap to the condenser. NOTE: Always replace the receiver-drier and bottom cap at the same time. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage. Be careful not to damage the radiator and condenser fins when installing the condenser. Charge the system, and test its performance.

The A/C Pressure Transducer (APT) converts the pressure value of high pressure line into voltage value after measuring it. By converted voltage value, engine ECU controls the cooling fan by operating it high speed or low speed. Engine ECU stops the operation of the compressor when the temperature of refrigerant line is very high or very low irregularly to optimize air conditioning system.

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1. Measure the pressure of high pressure line by measuring voltage output between terminal "1" and "2".
2. Inspect the voltage value whether it is sufficient to be regular value or not.
3. If the measured voltage value is not within specification, replace the A/C pressure transducer. Voltage = 0.00878835 * Pressure + 0.4

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1. Disconnect the negative (-) battery terminal.
2. Recover the refrigerant with a recovery/charging station.
3. Disconnect the A/C pressure transducer connector (A).
4. Remove the A/C pressure transducer (A). Tightening torque: 10 ~ 12 N.m (1.02 ~ 1.22 kgf.m, 7.4 ~ 8.8 lb-ft) CAUTION: Be careful not to bend the liquid & suction pipe.
5. Install in the reverse order of removal. NOTE: When installing, replace it with a new O-ring (A).

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

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1. Turn the ignition switch OFF.
2. Disconnect the evaporator temperature sensor connector.
3. Measure resistance between terminal "+" and "-" of the evaporator temperature sensor. PART SPECIFICATION Evaporator core temperature [°C (°F)] Resistance [Kohms] Voltage [V] -10 (14) 43.35 2.93 0 (32) 27.62 2.40 10 (50) 18.04 1.88 20 (68) 12.11 1.44 30 (86) 8.30 1.08 40 (104) 5.81 0.81
4. Connect the evaporator temperature sensor connector.
5. Run the engine and turn the A/C switch ON, then measure the voltage between the terminals of the harness connector.

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1. Disconnect the negative (-) battery terminal.
2. Remove the passenger side crash pad under cover (A).
3. Disconnect the evaporator temperature sensor connector (A).
4. Remove the evaporator temperature sensor (B) by pulling it out after rotating it 90° in a counterclockwise direction.
5. Install in the reverse order of removal.

An in-car air temperature sensor is located in the crash pad lower panel.

The sensor contains a thermistor which measures the temperature of the cabin. The signal determined by the resistance value which changes in accordance with perceived cabin temperature, is delivered to the heater control unit and according to this signal the control unit regulates the in-car temperature to the intended value.

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1. Turn the ignition switch ON.
2. Blow warm air into the in-car sensor air inlet. Measure the sensor resistance between 1 and 2 terminals. PART SPECIFICATION Temperature [°C(°F)] Resistance between terminals 1 and 2 (kohms) -30(-22) 509.57 -15(5) 216.07 0 (32) 97.71 15(59) 47.13 25(77) 30.00 35(95) 19.59 50(122) 10.81 60(140) - NOTE: An in-car sensor is a negative type thermistor. The resistance will rise with lower temperature, and reduce with higher temperature.

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1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad center panel (A). (Refer to «CRASH PAD CENTER PANEL»(/hyundai/santa-fe/iii-2012-2016/remont/gauges-instrument-panels/#crash-pad) .
3. Loosen the mounting screws and then remove the in-car sensor (A) located in the back side of the crash pad center lower panel.
4. Install in the reverse order of removal.

The photo sensor is located at the center of the defrost nozzles.

The photo sensor contains a photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light receiving portion, generates an electromotive force in proportion to the amount of radiation received which is transferred to the automatic temperature control module so that the solar radiation compensation will be performed.

1. Turn the ignition switch ON.
2. Connect the GDS.
3. Emit intensive light toward the photo sensor using a lamp, and check the output voltage change.
4. The voltage will rise with higher intensive light and reduce with lower intensive light.

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1. Disconnect the negative (-) battery terminal.
2. With a flat-head screwdriver, remove the photo sensor (A) from the center of the defrost nozzle after disconnecting the connector (B).
3. Install in the reverse order of removal.

The ambient temperature sensor is located at the front of the condenser and detects ambient air temperature. It is a negative type thermistor; resistance will increase with lower temperature, and decrease with higher temperature.

The sensor output will be used for discharge temperature control, temperature regulation door control, blower motor level control, mix mode control and in-car humidity control.

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Note. If the ambient temperature is below 2.0°C (35.6°F), the A/C compressor will stop. The compressor will operate manually.

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1. Turn the ignition switch OFF.
2. Remove the front bumper. (Refer to " «FRONT BUMPER COVER»(/hyundai/santa-fe/iii-2012-2016/remont/exterior-body-panels/#front-bumper-grille) ")
3. Disconnect ambient temperature sensor.
4. Check the resistance of the ambient temperature sensor between terminals 1 and 2 whether it changes by changing the ambient temperature. PART SPECIFICATION Ambient temperature [°C(°F)] Resistance between terminals 1 and 2 (kohms) -10(14) 158.18 0 (32) 95.10 10 (50) 58.80 20 (68) 37.32
5. If the measured resistance is not within specification, substitute with a known-good ambient temperature sensor and check for proper operation.
6. Replace the ambient temperature sensor if it is proved that there is a problem with the sensor.

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1. Disconnect the negative (-) battery terminal.
2. Remove the front bumper. (Refer to " «FRONT BUMPER COVER»(/hyundai/santa-fe/iii-2012-2016/remont/exterior-body-panels/#front-bumper-grille) ")
3. Disconnect the connector (A) and then remove the ambient temperature sensor (B).
4. Install in the reverse order of removal.

The auto defogging sensor is installed on the front window glass. The sensor judges and sends signal if moisture occurs to blow out wind for defogging. The air conditioner control module receives signal from the sensor and restrains moisture and eliminate defog by controlling the intake actuator, A/C, auto defogging actuator, blower motor RPM, and mode actuator.

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To inspect and diagnose the sensor, refer to SELF DIAGNOSIS .

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1. Disconnect the negative (-) battery terminal.
2. Remove the auto defogging sensor cover (A).
3. Disconnect the connector (A) and then remove the auto defogging sensor (B).
4. Install in the reverse order of removal.

The cluster ionizer makes disinfection and decomposition of bad smell from the air-conditioner or inflow air. And it cleans the inside air of a vehicle.

When the ignition switch is ON, the ionizer runs "CLEAN" mode and then "ION" mode, switching between both modes.

In the "CLEAN" mode, the cluster ionizer generates negative ions and positive ions to help clean smells from the air.

In the "ION" mode, the cluster ionizer generates negative ions and cleans inside air of a vehicle.

1. Press the MODE switch more then 4 times within 2 seconds while pressing the OFF switch.

* For diagnostic procedure, refer to DTC INDEX .

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1. Disconnect the negative (-) battery terminal.
2. Remove the passenger side crash pad under cover (A).
3. Remove the glove box housing. (Refer to " «GLOVE BOX HOUSING»(/hyundai/santa-fe/iii-2012-2016/remont/gauges-instrument-panels/#crash-pad) ")
4. Disconnect the cluster ionizer connector.
5. Remove the screws and then remove the cluster ionizer (A).
6. Install in the reverse order of removal.

See also:
• FRONT WHEEL GUARD
• DRIVE BELT
• FRONT BUMPER COVER
• CRASH PAD CENTER PANEL
• SELF DIAGNOSIS
• DTC INDEX
• REFRIGERANT LEAK TEST