SANTAFE(CM) > 2010 > G 2.

4 DOHC > Heating,Ventilation, Air Conditioning

Heating,Ventilation, Air Conditioning > General Information > Specifications

Specification

Air conditioner
Specification
Item
2.4 3.5
Type VS18 (Variable capacity)
Oil type & Capacity PAG(FD46XG)/140~160
Compressor
Pulley type 6PK-TYPE
Displacement 180cc/rev
Condenser Heat rejection 16,800 - 5% kcal/hr
The method to measure
A/C Pressure transducer Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA]
the pressure
Expansion valve Type Block
Type R-134a
Refrigerant
Capacity [oz(g)] 21.64 ± 0.88 (600 ±25)

Blower unit
Item Specification
Fresh and recirculation Operating method Actuator
Type Sirocco
Blower Speed step Auto + 8 speed (Automatic), 1~8speed (Manual)
Speed control Power transistor & High-relay(AUTO)
Air filter Type Particle filter

Heater and evaporator unit

Item Specification
Type Pin & Tube type
Heating capacity 4,600 ± 5% kcal/hr
Heater
Mode operating method Actuator
Temperature operating method Actuator
Temperature control type Evaporator temperature sensor
Evaporator ON : 2.1 ± 0.5 (35.78 ± 32.9),
A/C ON/OFF [°C (°F)]
OFF: 0.5 (32.9)

Heating,Ventilation, Air Conditioning > General Information > Troubleshooting

Troubleshooting

Problem Symptoms Table

Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant charge, air
flow or compressor.
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.
After correcting the malfunction, check the complete system to ensure that performance is satisfactory.
Standard:
1
 Symptom Suspect Area
1. Blower fuse
2. Blower relay
3. Blower motor
No blower operation
4. Power transistor
5. Blower speed control switch
6. Wire harness
1. Engine coolant capacity
No air temperature control
2. Heater control assembly
1. Refrigerant capacity
2. A/C Fuse
3. Magnetic clutch
4. Compressor
No compressor operation
5. A/C pressure transducer
6. A/C switch
7. Evaporator temperature sensor
8. Wire harness
1. Refrigerant capacity
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
No cool comes out
6. A/C pressure transducer
7. Evaporator temperature sensor
8. A/C switch
9. Heater control assembly
10. Wire harness
1. Refrigerant capacity
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
Insufficient cooling
6. Expansion valve
7. Evaporator
8. Refrigerant lines
9. A/C pressure transducer
10. Heater control assembly
1. Engine ECM
No engine idle-up when A/C switch ON
2. Wire harness
No air inlet control 1. Heater control assembly
1. Heater control assembly
No mode control
2. Mode actuator
1. Cooling fan fuse
2. Fan motor
No cooling fan operation
3. Engine ECM
4. Wire harness

Heating,Ventilation, Air Conditioning > General Information > Special Service Tools
Special Service Tools

Tool
Illustration Use
(Number and name)

2
09977-29000 Removal and installation of the disc &
Disc & hub assembly bolt remover hub assembly bolt

Heating,Ventilation, Air Conditioning > Air conditioning System > General Information
Instructions

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 the 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 that the 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 the 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:
A. When removing refrigerant components from a vehicle, cap immediately the components to prevent from the entry of
moisture.
B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the components.
C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from taking on
moisture.
D. Use the recommended lubricant from a sealed container only.
7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.

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.

3
When Installing Connecting Parts
Flange With Guide Pin
Check the new O-ring for damage and lubricate it using the specified compressor oil. Tighten the nut to specified torque.

Tightening torque [ N.m (kgf.m, lb-ft) ]

Size General bolt, nut
4T 7T
M6 5-6(0.5 - 0.6, 3.6 - 4.3) 9-11(0.9 - 1.1, 6.5 - 7.9)a
M8 12-14(1.2 - 1.4, 8.7 - 10) 20 - 26 (2.0 - 2.6, 14 - 18)
M10 25 - 28 (2.5 - 2.8, 18 - 20) 45 - 55 (4.5 - 5.5, 32 - 39)
Flange bolt, nut
Size
4T 7T
M6 5-7(0.5 - 0.7, 3.6 - 5.0) 8-12(0.8 - 1.2, 5.8 - 8.6)
M8 10-15(1.0 - 1.5, 7 - 10) 19 - 28 (1.9 - 2.8, 14 - 20)
M10 21 - 31 (2.1 - 3.1, 15 - 22) 39 - 60 (3.9 - 6.0, 28 - 43)

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 the 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 the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean and dry.

Heating,Ventilation, Air Conditioning > Air conditioning System > Description and Operation
Refrigeration Cycle
4
Heating,Ventilation, Air Conditioning > Air conditioning System > Repair procedures
Refrigerant System Service Basics

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.

- Air 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.
5
1. Connect an 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.

- Air 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.
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using
an R-134a refrigerant Recovery/Recycling/Charging System. (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 an 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 Leak Test.).
4. Remove the low pressure valve from the low-pressure service port.

6
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.

- Air 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.
1. Connect an 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 system that was removed during recovery. Use only specified refrigerant oil.
Charge the system with 29.98 ± 0.88 oz. (850 ± 25g) of 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.

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.

Heating,Ventilation, Air Conditioning > Air conditioning System > Components and
Components Location
Component Location Index

7
Engine Room

Interior

8
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor oil > Repair
procedures
Inspection

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 the 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 is circulating 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:

9
150 ± 10cc (5.07 ± 0.338 fl.oz)

Oil Return Operation

There is close affinity between the oil and the 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 be run in advance for oil return operation. The
procedure is as follows:
1. Open all the doors and the 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.

Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components
and Components Location
Component Location

10
 Components

1. Bolt 6. Retainer ring (Field Oil)

2. Disc & hub assembly 7. Field coil
3. Shim (Gap washer) 8. Screw
4. Retainer ring (Pulley) 9. Connector bracket
5. Pulley 10. Compressor assembly

Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair
procedures
Removal
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.
4. Loosen the drive belt.
5. Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines
immediately after disconnecting them to avoid moisture and dust contamination.

11
6. Disconnect the compressor clutch connector (A), and then remove 4 mounting bolts and the compressor.

Installation
1. Make sure of the length of compressor mounting bolts.

2. Install in the reverse order of removal, and note these items.

A. 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(5.29 oz.) the result is the amount of oil you should drain from the
new compressor (through the suction fitting).
B. 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.
C. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
D. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
E. 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.
F. Adjust the drive belt.
G. Charge the system and test its performance.

Inspection
1. Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is damage,
replace the clutch set.
2. Check the pulley (B) 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.

12
3. Measure the clearance between the pulley (B) and the disc & hub assembly (A) all the way around. If the clearance is not
within specified limits, remove the disc & hub assembly and add or remove shim (gap washer) as needed to increase or
decrease clearance.

Clearance: 0.45 ± 0.1mm (0.018 ± 0.004 in.)

The shims (gap washers) are available in seven thicknesses: 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm and
1.3mm.

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.

Disassembly
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.

Tightening torque :
10~15N.m (1.02~1.53kgf.m, 7.37~11lb-ft)

13
2. Remove the disc & hub assembly (A) and shim (gap washer) (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.

3. If you removal the field coil, remove retainer ring (A) with retainer ring pliers.

- 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. Remove the retainer ring (B) and then remove the field coil (C)
from the shaft with a puller. Be careful not to damage the coil and compressor.

5. Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
A. Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
B. Install new retainer rings, and make sure they are fully seated in the groove.
14
 C. Make sure that the pulley turns smoothly after its reassembled.

Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Components
and Components Location
Component Location

Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Repair
procedures
Inspection
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.

Replacement

Condenser Assembly
1. Recover the refrigerant with a recovery/ recycling/ charging station.
2. Disconnect the negative (-) battery terminal.
3. Remove the radiator. (Refer to EM- Radiator)
4. Remove 2 bolts, and then remove the condenser (A) by lifting it up. Be careful not to damage the radiator and condenser
fins when removing the condenser.

15
5. Install in the reverse order of removal, and note these items :
A. If you're installing a new condenser, add refrigerant oil ND-OIL8.
B. 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.
C. Be careful not to damage the radiator and condenser fins when installing the condenser.
D. Be sure to install the lower mount cushions of condenser securely into the holes.
E. Charge the system, and test its performance.

Desiccant
1. Remove the condenser, and then remove the bottom cap (B) with L wrench (A) from the condenser.

Tightening torque :
20~25N.m (2.0~2.5kgf-m, 14.5~18.2lb-ft)

2. Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged bottom cap
filter.

3. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
4. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed to air for
use.
5. Install the new bottom cap to the condenser.

- Always replace the desiccant 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

16
 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.
- Be sure to install the lower mount cushions of condenser securely into the holes.
- Charge the system, and test its performance.

Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line >
Components and Components Location
Component Location

Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Repair
procedures
Replacement
1. Discharge refrigerant from refrigeration system.
2. Replace faulty tube or hose.

Cap the open fittings immediately to keep moisture or dirt out of the system.

3. Tighten joint of bolt or nut to specified torque.

Connections should not be tighter than the specified torpue.

17
 Part tightened N.m Kgf.m lb-ft
Condenser - Discharge hose
Condenser - Liquid tube
0.8~
Compressor - Discharge hose 8 ~ 12 5.8 ~ 8.7
1.2
Compressor - Suction hose
Expansion valve - Evaporator

4. Evacuate air in refrigeration system and charge system with refrigerant.

600 ± 25(g) (21.164 ± 0.88 [oz])

5. Inspect for leakage of refrigerant.

Using a gas leak detector, check for leakage of refrigerant.
6. Inspect A/C operation.

Heating,Ventilation, Air Conditioning > Air conditioning System > A/C pressure transducer >
Components and Components Location
Component Location

18
Heating,Ventilation, Air Conditioning > Air conditioning System > A/C pressure transducer >
Description and Operation
Description
The A/C presssur transducer converts the pressur value of the high pressur line into a voltage value after measurement. The
ECM controls the coolings fan speed based of the converted voltage valu. The ECM also stops the operation of the
compressor when the temperature of the refrigerant line it too high or low to for optimal operation.

Heating,Ventilation, Air Conditioning > Air conditioning System > A/C pressure transducer >
Repair procedures
Inspection
1. Measure the pressure of high pressure line by measuring voltage output between NO.1 and NO.2 terminals.

2. Verify that the voltage value is within specification.

Voltage = 0.00878835 * Pressure + 0.37081095 [PSIA]

3. If the measured voltage value is not specification, replace the A/C pressure transducer.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Verify that the voltage value is within specification.
3. Disconnect A/C pressure transducer connector (3P) (A).

Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature
sensor > Components and Components Location
Component Location

19
Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature
sensor > Description and Operation
Description
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay power in
order to prevent evaporator freezing by excessive cooling.

Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature
sensor > Repair procedures
Inspection
1. Ignition "OFF"
2. Disconnect evaporator temperature sensor.
3. Using the multi-tester, Measure resistance between terminal "1" and "2" of evaporator temperature sensor.

Specification

20
 Evaporator core temperature Resistance
[°C(°F)] [K]
-10(14) 43.35
-5(23) 34.48
0(32) 27.62
5(41) 22.27
10(50) 18.07
15(59) 14.75
20(68) 12.11
25(77) 10.00
30(86) 8.30
35(95) 6.93
40(104) 5.81
45(113) 4.90
50(122) 4.15

4. If the measured resistance is within specification, substitute with a known-good evaporator temperature sensor and check
for proper operation.
5. If the problem is corrected, replace the evaporator temperature sensor.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the center lower side cover (A).

3. Disconnect the evaporator sensor connector (A).

4. Remove the evaporator temperature sensor(B), by pulling it after rorating 90° in a counterclockwise direction.

Take care that evaporator core pins are not bent.

5. Installation is the reverse order of removal.

21
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Components
and Components Location
Component Location

Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Description
and Operation
Description
1. In-car air temperature sensor is located inside of the cresh pad panel.
2. The sensor contains a thermistor which measures the temperature of the inside. The signal, decided by the resistance
value which changes in accordance with perceived inside temperature, is delivered to heater control unit and according to
this signal the control unit regulates incar temperature to intended value.

Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Repair
procedures
Inspection
1. Ignition "ON"

22
2. Blow air with changing temperature to the in car sensor air inlet. Measure sensor resistance between 2 and 4 terminals.

Specification
Temperature [°C(°F)] Resistance between terminals 2and 4 (k)
60(140) 7.463 ± 2.6%
50(122) 10.810 ± 2.2%
35(95) 19.59 ± 1.6%
25(77) 30.00 ± 1.2%
15(59) 47.130 ± 1.7%
0(32) 97.710 ± 2.4%
-15(5) 216.1 ± 3.2%
-30(-22) 509.36 ± 4.1%

In car sensor is negative type thermistor that resistance will rise with lower temperature, and reduce with higher
temperature.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Disconnect the connector of in-car sensor (A).Loosen the mounting 1 screws and then remove the in-car sensor (B).

3. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Components
and Components Location
Component Location

23
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Description
and Operation
Description
1. The photo sensor (A) is located at the center of defrost nozzle.
2. 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.

Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Repair
procedures
Inspection
1. Ignition "ON"
2. Using the scan tool.
3. Emit intensive light toward 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.

24
 Replacement
1. Disconnect the negative (-) battery terminal.
2. With the (-) driver, remove the photo sensor (B) from the center of defrost nozzle (A).

3. Install in the reverse order of removal.

Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor >
Components and Components Location
Component Location

25
Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor >
Description and Operation
Description
1. Water temperature sensor is located at the heater unit.
2. It detects coolant temperature. Its signal is used for cold engine lockout control. When the driver operates the heater
before the engine is warmed up, the signal from sensor causes the heater control unit to reduce blower motor speed until
coolant temperature reaches the threshold value.

Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor >
Repair procedures
Inspection
1. Ignition "ON"
2. Using the multi-tester, Measure resistance between terminal "1" and "2" of water temperature sensor.

Specification
Coolant temperature [°C(°F)] Resistance (k) Voltage (V)

26
 -10(14) 55.85 ± 3% 4.24 ± 3%
0(32) 32.91 ± 3% 3.83 ± 3%
10(50) 19.99 ± 3% 3.33 ± 3%
20(68) 12.51 ± 3% 2.78 ± 3%
30(86) 8.047 ± 3% 2.23 ± 3%
40(104) 5.311 ± 3% 1.73 ± 3%
50(122) 3.588 ± 3% 1.32 ± 3%
60(140) 2.476 ± 3% 0.99 ± 3%
70(158) 1.742 ±3% 0.74 ± 3%
80(176) 1.246 ± 3% 0.55 ± 3%

3. If the measured resistance is not specification, substitute with a known-good water temperature sensor and check for
proper operation.
4. If the problem is corrected, replace the water temperature sensor.

Negative type thermistor that resistance will rise with lower temperature, and reduce with higher temperature.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the console side cover. (Refer to BD group-center console)
3. Disconnect the connector (A) of water temperature sensor and then remove the water temperature sensor (B) by pulling
out.

4. Installation is the reverse order of removal.

Take care that wire of water temperature sensor is not to be damaged

Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor >
Components and Components Location
Component Location

27
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor >
Description and Operation
Description
1. 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 temperatures.
2. 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.

During AUTO mode the A/C compressor will be stopped when the ambient temperature is below 2.0°C(35.6°F).
The compressor can still be turned on with manual control.

Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Repair
procedures

28
 Inspection
1. Ignition "OFF"
2. Disconnect ambient temperature sensor.
3. Check the resistance of ambient temperature sensor between terminals 1 and 2 whether it is changed by changing of the
ambient temperature.
Specification
Ambient temperature Resistance between
[°C(°F)] terminals 1and 2 (k)
-30(-22) 480.41
-20(-4) 278.85
-10(14) 162.38
0(32) 95.10
10(50) 58.80
20(68) 36.50
30(86) 24.26
40(104) 16.13
50(122) 10.95
60(140) 7.58

4. If the measured resistance is not specification, substitute with a known-good ambient temperature sensor and check for
proper operation.
5. If the problem is corrected, replace the ambient temperature sensor.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the front bumper. (Refer to BD group-front bumper)
3. Remove the ambient temperature sensor (A).

4. Installation is the reverse order of removal.

29
Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Components and Components
Location
Component Location

Components

30
1. Mode control actuator 7. Temp control door (Dual type)
2. Mode cam 8. Lower case
3. Heater & Evaporator case (L) 9. Water temperature sensor
4. Defrost door 10. Heater core
5. Vent door 11. Heater core cover
6. Temp control door (Single type) 12. Temp control actuator

31
1. Evaporator case seal 5. Plenum duct
2. Evaporator core 6. Temp control actuator
3. Evaporator temprature sensor 7. Heater & Evaporator case (R)
4. Plenum duct seal 8. Separator (Dual type only)

Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Repair procedures
Replacement
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 bolts (A) and the expansion valve (B) from the evaporator core.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

32
5. Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.

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.

6. Remove the crash pad. (Refer to BD group-crash pad)

7. Remove the cowl cross bar assembly. (Refer to BD group-crash pad)
8. Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator
temperature sensor and blower motor.
9. Remove the heater & blower unit after loosening 3 mounting bolts.

10. Remove the blower unit (B) from heater unit after loosening 3 screws.

33
11. Remove the water temperature sensor. (Refer to HA - Water temp sensor)
12. Remove the heater core (B) after remove the cover (A).

13. Loosen a screw and then remove the heater unit cover(A).

14. Remove the evaporator core(A).

15. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core.
16. Install the heater core in the reverse order of removal.
17. Installation is the reverse order of removal, and note these items :
A. If you're installing a new evaporator, add refrigerant oil (ND-OIL8).
B. 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.
C. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
D. 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
E. Apply sealant to the grommets.
F. Make sure that there is no air leakage.
G. Charge the system and test its performance.
H. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
I. Refill the cooling system with engine coolant.

Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Components
and Components Location
Component Location
34
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Description
and Operation
Description
1. Heater unit includes mode control actuator and temperature control actuator.
2. Temperature control actuator is located at the heater unit. It regulates the temperature by the procedure as follows. Signal
from control unit adjusts position of temperature door by operating temperature switch and then temperature will be
regulated by the hot/cold air ratio decided by position of temperature door

Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Repair
procedures
Inspection
1. Ignition "OFF"
2. Disconnect the connector of temperature control actuator.
3. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 3 and
grounding terminal 4.
35
 Verify that the temperature control actuator operates to the cool position when connecting in the reverse.

[Driver]

Specification
Door position Voltage (6-7) Error detecting
Low voltage :
Max. cooling 0.3 ± 0.15V
0.1V or less
High voltage :
Max. heating 4.7 ± 0.15V
4.9V or more

[Passenger]

Specification
Door position Voltage (5-6) Error detecting
Low voltage :
Max. cooling 0.3 ± 0.15V
0.1V or less
High voltage :
Max. heating 4.7 ± 0.15V
4.9V or more

It will feedback current position of actuator to controls.

4. If the measured voltage is not specification, substitute with a known-good temperature control actuator and check for
proper operation.
5. If the problem is corrected, replace the temperature control actuator.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the driver’s crash pad lower panel (Refer to BD- Crash pad)
3. Disconnect the temperature control actuator connector (A) after removing the air duct.
4. Loosen the mounting screw and then remove the temperature control actuator (B).

[Passenger's]

36
 [Driver's]

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Components and
Components Location
Component Location

37
Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Description and
Operation
Description
The mode control actuator is located at the heater unit.
It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit. Pressing mode select
switch makes the mode control actuator shift in order of vent B/L  floor  mix  def.

Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Repair procedures
Inspection
1. Ignition "OFF"
2. Disconnect the connector of mode control actuator.
3. Verify that the mode control actuator operates to the defrost mode when connecting 12V to the terminal 3 and grounding
terminal 4.
4. Verify that the mode control actuator operates to the vent mode when connecting in the reverse.

38
5. Check the voltage between terminals 5 and 7.
Door position Voltage (5-7) Error detecting
Low voltage :
Vent 0.3 ± 0.15V
0.1V or less
High voltage :
Defrost 4.7 ± 0.15V
4.9V or more

It will feedback current position of actuator to controls.

6. If the measured voltage is not specification, substitute with a known-good mode control actuator and check for proper
operation.
7. If the problem is corrected, replace the mode control actuator.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the driver’s crash pad lower panel (Refer to BD group-crash pad).
3. Disconnect the temperature control actuator connector (A) after removing the air duct.
4. Loosen the mounting screw and then remove the temperature control actuator (B).

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Components and Components
Location
Component Location

39
Components

40
1. Intake duck seal 7. Blower upper case
2. Air inlet case 8. Blower lower case
3. Intake door assembly 9. Blower seal
4. Intake actuator 10. Blower motor
5. Air filter 11. Mos-Fet
6. Air filter housing

Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Repair procedures
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad.(Refer to BD group-crash pad)
3. Disconnect the connectors from the intake actuator, the blower motor and blower resister.
4. Remove the blower unit (A) from the heater unit after loosening a mounting bolt and 3 screws.

41
 Make sure that there is no air leaking out of the blower and duct joints.

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Components and
Components Location
Component Location

42
Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Repair procedures
Inspection
1. Connect the battery voltage and check the blower motor rotation.

2. If the blower motor voltage is not operated well, substitute with a known-good blower motor and check for proper
operation.

43
 Manual Auto
1 3.8V AUTO LO(4.5V)
2 4.9V 4.6~5.5V
3 6.1V 5.6~6.7V
4 7.2V 6.8~7.7V
5 8.3V 7.8~8.9V
6 9.5V 9.0~10.1V
7 10.6V 10.2~AUTO HI(10.6V)
8 B+

3. If the problem is corrected, replace the blower motor.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the blower under cover. (Refer to BD group-crash pad)
3. Disconnect the connector (A) of the blower motor.

4. Remove the blower motor (A) after loosening the mounting screws.

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Blower > Power Mosfet > Components and
Components Location
Component Location

44
Heating,Ventilation, Air Conditioning > Blower > Power Mosfet > Repair procedures
Inspection
1. Ignition "ON"
2. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2.
3. Select the control switch to raise voltage until high speed.

[Specification]
Motor Voltage
Fan
Manual
First speed 3.8 ±0.5V
Second speed 4.9 ±0.5V
Third speed 6.1 ±0.5V

45
 Fourth speed 7.2 ±0.5V
Fifth speed 8.3 ±0.5V
Sixth speed 9.5 ±0.5V
Seventh speed 10.6 ±0.5V
eighth speed BAT(+)

*AUTO COOLING: Auto speed (4.5V~B+)

*AUTO HEATING: Auto speed (4.5V~10.5V)
4. If the measured voltage is not specification, substitute with a known-good power mosfet and check for proper operation.
5. If the problem is corrected, replace the power mosfet.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Disconnect the power mosfet connector (A) at the connecting part between heater and blower unit.
3. Remove the power mosfet(B) after loosening the mounting screws.

4. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Description and
Operation
Description
This has particle filter which eliminates foreign materials and odor. The particle filter includes odor filter as well as conventional
dust filter to ensure comfortable interior environment.

Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Repair procedures
Replacement
1. Open the glove box (B).
Lower the glove box down completely by removing the glove box stopper (A) to the glove box.

46
2. Remove the glove box(B) from the left(A).

3. Remove the filter cover (A) with pushing the knob.

4. Replace the air filter (B).

In case of driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as possible.

Replacement period:
Approximately 15,000 km or 10,000 miles

Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Components and
Components Location
Component Location

47
Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Description and Operation
Description
1. The intake actuator is located at the blower unit.
2. It regulates the intake door by signal from control unit.
3. Pressing the intake selection switch will shift between recirculation and fresh air modes.

Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Repair procedures
Inspection
1. Ignition "OFF"
2. Disconnect the intake actuator connector.
3. Verify that the actuator operates to the recirculation position when connecting 12V to the terminal 3 and grounding terminal
4.
4. Verify that the intake actuator operates to the fresh position when connecting in the reverse.

5. If the intake actuator is not operated well, substitute with a known-good intake actuator and check for proper operation.

48
6. If the problem is corrected, replace the intake actuator.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the glove box. (Refer to BD group-crash pad)
3. Disconnect the intake actuator connector.
4. Loosen the mounting screw and then remove the intake actuator (A) from the blower unit.

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Manual) >
Components and Components Location
Component

49
[Connector Pin Function]
Connector PIN NO. Function Connector PIN NO. Function
1 TAIL LAMP 14 RHEOSTAT (ILL-)
2 BATTERY 15 FET (G)
3 A/C OUT PUT 16 FET (D)
4 MODE ACT'R (VENT) 17 TEMP ACT'R F/B
5 MODE ACT'R (DEF) 18 MODE ACT'R F/B
Connector (B) 6 TEMP ACT'R (COOL) Connector (B) 19 INTAKE ACT'R F/B
7 TEMP ACT'R (WARM) 20 EVAP SENSOR (+)
8 INTAKE ACT'R (FRE) 21 BLOWER MOTOR (+)
9 INTAKE ACT'R (REC) 22 A/C SELECT SIGNAL
DEF INDICATOR
10 DEF SELECT SIGNAL 23
OUTPUT

50
 11 SENSOR REF(+5V) 24 SENSOR GND
12 - 25 -
13 IGN2 26 GND

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Manual) > Repair
procedures
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad center lower garnish(A).

3. Remove the heater & A/C controller (A) after loosening 4 screws.

4. Dissconnect the connector(A).

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full Automatic)
> Components and Components Location
Component

51
[Connector Pin Function]
Connector PIN NO. Function Connector PIN NO. Function
1 TAIL LAMP 1 SENSOR REF(+5V)
2 BATTERY 2 AQS SIGNAL
3 A/C OUTPUT 3 AMB SENSOR(+)
4 A/C SELECT SIGNAL 4 -
5 - 5 INCAR SENSOR(+)
Connector(A) Connector(B)
6 K-LINE 6 EVAP. SENSOR(+)
WATER TEMP
7 - 7
SENSOR(+)
8 DEF SELECT SIGNAL 8 SENSOR REF(+5V)
DEF INDCATOR
9 9 FET (G)
OUTPUT

52
 10 - 10 FET (D)
11 - 11 BLOWER MOTOR (+)
12 IGN2 12 SENSOR GND
TEMP ACT’R DR
13 IGN2 13
(COOL)
TEMP ACT’R DR
14 RHEOSTAT 14
(WARM)
15 - 15 DR PHOTO (-)
TEMP ACT’R
16 16 PS PHOTO (-)
PS(COOL)
TEMP ACT’R
17 17 INCAR MOTOR (-)
PS(WARM)
18 TEMP ACT’R PS F/B 18 TEMP ACT’R DR F/B
19 MODE ACT’R(VENT) 19 BLOWER ON SIGNAL
20 MODE ACT’R(DEF) 20 -
21 MODE ACT’R F/B 21 -
22 INTAKE ACT’R (FRE) 22 -
23 INTAKE ACT’R (REC) ᇫ ᇫ
24 INTAKE ACT’R F/B ᇫ ᇫ
25 GND ᇫ ᇫ
26 GND ᇫ ᇫ

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full Automatic)
> Troubleshooting
Selfdiagnosis
1. Self-diagnosis process

2. How to read self-diagnostic code

After the display panel flickers three times every 0.5 second, the corresponding fault code flickers on the setup
53
 temperature display panel every 0.5 second and will show two figures. Codes are displayed in numerical format
Fault code
Fault code
Fail description
Control unit DTC
00 - Normal
11 B1234 In-car temperature sensor open
12 B1233 In-car temperature sensor short
13 B1238 Ambient temperature sensor open
14 B1237 Ambient temperature sensor short
15 B1202 Water temperature sensor open
16 B1203 Water temperature sensor short
17 B1242 Evaporator temperature sensor open
18 B1241 Evaporator temperature sensor short
19 B1245 Temperature control actuator feed back open (Drive's)
19 B1246 Temperature control actuator feed back short (Drive's)
20 B2406 Temperature control actuator failure
21 B1249 Mode control actuator open
21 B1250 Mode control actuator short
22 B2409 Mode control actuator failure
25 B1208 Intake potentiometer open
25 B1209 Intake potentiometer short
26 B2408 Intake potentiometer failure
32 B1204 Temperature control actuator open (Passenger's)
32 B1205 Temperature control actuator short (Passenger's)
33 B2415 Temperature control actuator failure

3. Fault code display

(1) Continuance operation : DTC code is one.

(2) Continuance operation : DTC code is more two.

(3) STEP operation

A. Nomal or one fault code is same as a continuance operation.
B. DTC code os more two.

54
4. Diagnostic procedure refer to DTC code.
5. Fail safe
(1) In-car temperature sensor: Control with the value of 25°C(77°F)
(2) Ambient temperature sensor: Control with the value of 20°C(67°F)
(3) Evaporator temperature sensor: Control with the value of -2°C(28.4°F)
(4) Temperature sensor : Control with the value of -2°C (28.4°F)
(5) Temperature control actuator (Air mix potentiometer):
If temperature setting 17°C-24.5°C, fix at maximum cooling position.
If temperature setting 25°C-32°C, fix at maximum heating position.
(6) Mode control actuator (Direction potentiometer):
Fix vent position, while selecting vent mode.
Fix defrost position, while selecting all except vent mode.
(7) Intake control actuator :
Fix fresh position, while selecting fresh mode.
Fix recirculation position, while selecting recirculation mode.

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full Automatic)
> Repair procedures
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad center lower garnish(A).

3. Remove the heater & A/C controller (A) after loosening 4 screws.

55
4. Dissconnect the connector(A).

5. Installation is the reverse order of removal.

56