Heating, Ventilation & Air Conditioning: Removal & Installation Hyundai Sonata V рестайлинг

REPLACEMENT OF COMPONENT PARTS

When replacing the system component parts, supply the following amount of oil to the component parts to be installed.

COMPONENT SPECIFICATION

For compressor replacement, subtract the volume of oil drained from the removed compressor from the specified volume, and drain the calculated volume of oil from the new compressor

The specified volume-volume of removed compressor = volume to drain from the new compressor.

Note. Even if no oil is drained from the removed compressor, don't drain more than 50cc from new compressor.

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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 cable from the battery.
3. Recover the refrigerant with a recovery/charging station (Refer to «REFRIGERANT RECOVERY»(ref-286583-S39158340492008060300000) ).
4. Loosen the drive belt (Refer to the «TIMING»(ref-286582-S04301053162008060300000) ).
5. Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug (C) or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
6. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B).

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1. Remove the center bolt (A) while holding the disc & hub assembly with a commercially available disc & hub assembly bolt remover; Special tool number 09977-29000. TORQUE : 10~15 N.m (1.02~1.53 kgf.m, 7.5~11.3 lb-ft)
2. Remove the disc & hub assembly (A) and shim (B), taking care not to lose the shims. If the clutch needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the disc & hub assembly, and recheck its clearance (Refer to «INSPECTION»(ref-286583-S37603090882008060300000) ).
3. If you remove the field coil, remove retainer ring (A) with retainer ring pliers. NOTE: Be careful not to damage the pulley (B) and compressor during removal/installation. Once retainer ring (A) is removed, replace it with a new one.
4. Remove the screw (A) from the field coil ground terminal and then remove the field coil (B) and retainer ring (C).
5. Reassemble the compressor clutch in the reverse order of disassembly, and note these items: Clean the pulley and compressor sliding surfaces with non-petroleum solvent. Install new retainer rings, and make sure they are fully seated in the groove. Make sure that the pulley turns smoothly after its reassembled.

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1. Check the plated parts of the disc & hub assembly for color changes, peeling or other damage. If there is damage, replace the clutch set.
2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag.
3. Measure the clearance between the pulley (A) and the disc & hub assembly (B) all the way around. If the clearance is not within specified limits, remove the disc & hub assembly (Refer to «REMOVAL»(ref-286583-S09390580832008060300000) ) and add or remove shims as needed to increase or decrease clearance. Clearance : 0.5 ± 0.15mm (0.020 ± 0.006 in.) NOTE: The shims are available in eight thicknesses: 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm, 1.3mm and 1.4mm
4. Check operation of the magnetic clutch. Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the compressor body. Check the magnetic clutch operating noise to determine the condition.

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1. Make sure of the length of compressor mounting bolts, and then tighten it A-->B°C-->D order. TORQUE : 20~33 N.m (2.04 ~ 3.36 kgf.m, 14.7~24.3 lb-ft)
2. Install in the reverse order of removal, and note these items. If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure its volume, Subtract the volume of drained oil from 150cc the result is the amount of 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. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Adjust the drive belt (Refer to the «TIMING»(ref-286582-S04301053162008060300000) ) Charge the system and test its performance.

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REPLACEMENT

1. Discharge refrigerant from refrigeration system (Refer to «REFRIGERANT RECOVERY»(ref-286583-S39158340492008060300000) ).
2. Replace faulty tube or hose. CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system.
3. Tighten joint of bolt or nut to specified torque. CAUTION: Connections should not be torque tighter than the specified torque. TORQUE SPECIFICATION Part tightened N.m kgf.m lb-ft Condenser x Discharge hose 5 ~ 7 0.5 ~ 0.6 3.7 ~ 5.2 Condenser x Liquid tube Compressor x Discharge hose 5 ~ 7 0.5 ~ 0.6 3.7 ~ 5.2 Compressor x Suction hose Expansion valve x Evaporator 12 ~ 15 1.2 ~ 1.5 8.7 ~ 10.8
4. Evacuate air in refrigeration system and charge system with refrigerant (Refer to «REFRIGERANT RECOVERY»(ref-286583-S39158340492008060300000) ). Specified amount : 550 ± 25g (19.4 ± 0.88 oz.)
5. Inspect for leakage of refrigerant. Using a gas leak detector, check for leakage of refrigerant (Refer to «REFRIGERANT LEAK TEST»(ref-286583-S18205409912008060300000) ).
6. Inspect A/C operation.

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1. Disconnect the negative (-) battery terminal.
2. Remove the lower crash panel (A) (Refer to «CRASH PAD»(ref-286589-S22159734202008060300000) ).
3. Disconnect humidity sensor connector.
4. Loosen the mounting screws (B) and then remove the humidity sensor (C).
5. Installation is the reverse order of removal.

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1. Disconnect the negative (-) battery terminal.
2. Recover the refrigerant with a recovery/recycling/charging station.
3. When the engine is cool, drain the engine coolant from the radiator.
4. Remove the expansion valve cover after loosening the nut (A).
5. Remove the expansion valve (C) from evaporator core after loosening nuts. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
6. Disconnect the inlet (A) and outlet (B) heater hoses from the heater unit. CAUTION: Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately.
7. Remove the crash pad. (Refer to «CRASH PAD»(ref-286589-S22159734202008060300000) )
8. Remove the cowl cross member. )
9. Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator temperature sensor, then remove the mounting nut and the mounting bolts.
10. Remove the heater & evaporator unit after loosening the mounting bolts.
11. Remove the blower unit from heater unit after loosening fixing screws on the connected part.
12. Remove the side bracket (A) and heater core (B).
13. Be careful that inlet and outlet pipes are not to be bent during heater core removal, and pull out the heater core.
14. Install the heater core in the reverse order of removal.
15. Install in the reverse order of removal, and note these items: If you're installing a new evaporator, 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. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Apply sealant to the grommets. Make sure that there is no air leakage. Charge the system and test its performance. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely. Refill the cooling system with engine coolant.

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1. Disconnect the negative (-) battery terminal.
2. Remove the heater & blower unit (Refer to «BLOWER UNIT»(ref-286583-S21584576392008060300000) )
3. Disconnect the connectors from the intake actuator, blower relay, the blower motor, resistor (MANUAL) and power mosfet (AUTOMATIC).
4. Remove the self-tapping screws and the blower unit. NOTE: Make sure that there is no air leaking out of the blower and duct joints.
5. Install in the reverse order of removal.

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1. Connect the battery voltage and check the blower motor rotation.
2. If the blower motor does not operate properly, substitute with a known-good blower motor and check for proper operation.
3. If the problem is corrected, replace the blower motor.

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1. Disconnect the negative (-) battery terminal.
2. Remove the under cover after loosening 2 screws.
3. Disconnect the connector of the blower motor.
4. Remove the blower motor (A) after loosening the mounting 3 screws.
5. Installation is the reverse order of removal.

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1. Disconnect the negative (-) battery terminal.
2. Remove the passenger compartment relay box. Check for continuity between the terminals.
3. There should be continuity between the No.9 in the I/P-K and No. 15 in the I/P-A terminals when power and ground are connected to the No.16 in the I/P-D and No. 13 I/P-B terminals in the passenger compartment relay box.
4. There should be no continuity between the No.9 in the I/P-K and No. 15 in the I/P-A terminals when power is disconnected.
5. If the blower motor voltage does not operate properly, substitute with a known-good blower relay and check for proper operation.
6. If the problem is corrected, replace the blower relay.

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1. There should be continuity between the No.3 and No.4 terminals when power and ground are connected to the No.1 and No.2 terminals.
2. There should be no continuity between the No.3 and No.4 terminals when power is disconnected.

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1. Disconnect the negative (-) battery terminal.
2. Remove the power mosfet. Measure resistance between Drain and Source using resistance tester. You can estimate whether power mosfet is failure or not referring to the specification. FET FAIL CHECK RESISTANCE SPECIFICATION Resistance (Drain-Source) Specification Measuring method 1 2 Mosfet Drain + - Source - + Classification Normal infinity About 3Mohms Short About 0~300ohms About 0~300ohms Open infinity infinity
3. If the measured resistance is not normal specification, replace the power mosfet.
4. If it is normal, install the power mosfet and ignition "ON". Manually operate the control switch and measure the voltage between pin 1 and 2 of blower motor.
5. Select the control switch to raise voltage until high speed. VOLTAGE SPECIFICATION Fan Motor voltage(V) ± 0.5V First speed 3.8 Second speed 4.9 Third speed 6.1 Fourth speed 7.2 Fifth speed 8.3 Sixth speed 9.5 Seventh speed 10.6 Eighth speed Battery (+)
6. If the measured voltage is not within specification, substitute with a known-good power mosfet and check for proper operation.
7. If the problem is corrected, replace the power mosfet.

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1. Disconnect the negative (-) battery terminal.
2. Disconnect the connector of the power mosfet at the below blower unit.
3. Remove the power mosfet (A) after loosening the mounting screws.
4. Install in the reverse order of removal.

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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)

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1. Disconnect the negative (-) battery terminal.
2. Disconnect the connector of the blower resistor at the below blower unit.
3. Remove the blower resistor (A) after loosening the mounting screws.
4. Install in the reverse order of removal.

1. Disconnect the negative (-) battery terminal.
2. Remove the center facia panel (A) after pulling it by using a regular screw driver (-).
3. Disconnect the connectors (B) from the center facia.
4. Remove the heater & A/C controller (C).
5. Install in the reverse order of removal.

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