Kia air conditioning diagnosis

Refrigeration SystemThe refrigeration system consists of the A/C compressor, the receiver/dryer, the evaporator, the condenser, the expansion valve, the dual pressure switch and the refr

S E E R R V V II C C E E T T R R A A II N N II N N G G

Kia Air Conditioning Diagnosis

Course Introduction

Appropriate service methods and proper repair dures are essential for the safe, reliable operation of allmotor vehicles as well as the personal safety of the indi-vidual doing the repair There are numerous variations

proce-in procedures, techniques, tools, and parts for servicproce-ingvehicles, as well as in the skill of the individual doing thework This manual cannot possibly anticipate all suchvariations and provide advice or caution to each

Accordingly, anyone who departs from the instructionprovided in this manual must first establish that he com-promises neither his personal safety nor the vehicleintegrity by his choice of methods, tools, or parts Thefollowing list contains general warnings that shouldalways be followed while working on a vehicle

• Always wear safety glasses for eye protection

• Use safety stands whenever a procedure requiresunderbody work

• Be sure ignition switch is always off unless wise specified by a procedure

other-• Set the parking brake when working on the vehicle

• Operate the engine only in a well ventilated area

• Keep clear of moving parts when engine is running

• To prevent serious burns, avoid contact with hotmetal parts such as the radiator, exhaust manifold,tail pipe, catalytic converter and muffler

• Do not smoke while working on a vehicle

To provide Kia technicians

with the skills and knowledge

required to diagnose and

repair a vehicle that has an air

conditioning system

malfunction.

ACD-2

WELCOME TO:

Kia Air Conditioning Diagnosis

• Hands-on practice with Kia

diagnostic tools.

• Review of available resources.

Course length is one day.

ACD-1

C

COOUURRSSEE IINNTTRROODDUUCCTTIIOONNThis course provides an opportunity for

observed hands-on practice diagnosing the

cause of Kia air conditioning complaints usingvarious types of tests and diagnostic tools Inpreparation to meet this goal, you will:

• Identify normal operation of a Kia airconditioning system

• Learn to use the Kia 5-step diagnosis process

P

PRREEREQQUUIISSIITTEESS

1 Successful completion of the Kia ProductFamiliarization course

2 ASE A7, or equivalent, is highlyrecommended

• Helps you focus your efforts

in the areas that are of the

most value to you.

of training that a technician needs depends onfactors like technical background, productknowledge and practical experience To meet

your needs, we have developed a modular

training system to help you focus your efforts inthe areas that are of the most value to you.T

TWWOO TTYYPESS OOFF MMOODDUULLEESS1

1 SSttuuddeenntt LLeeaarrnniinngg GGuuiiddee aanndd WWoorrkkbbooookk::These modules explain subjects from basicconcepts to the most complex technology

we offer Obtaining a working knowledge

of any system or component is aprerequisite to effectively diagnose systemmalfunctions These modules may alsoinclude classroom exercises that you willcomplete as a group

22 GGuuiiddeedd PPrraaccttiiccee::

These modules provide hands-onexperience, building on the theory anddiagnosis topics covered earlier

These modules also help you developtroubleshooting skills and often involve theuse of service manuals, ETM’s, technicalservice bulletins, newsletters, and otherresources as an integral approach to youroverall diagnostic strategy

learning plan illustrated in the Course Activities Guide that is on the next page.

After completing the required modules, you

will take a Final Test to verify your

understanding of the course subject areas thatwere covered in the course

When you see this symbol, view the appropriate video segment for important concepts or procedures.

Activities support critical learning objectives.

Performing these procedures will help you master the material.

This symbol shows when you must refer to additional publications to complete the questions or module activity.

Most modules contain a Self-Test or an Instructor off to give you feedback on your strengths and

Sign-weaknesses Gauge your level of expertise by your ability to answer the questions and instructor's feedback Review appropriate areas as needed.

KIIAA AAIIRR CCOONNDDIITTIIOONNIINNGG DDIIAAGGNNOOSSIISS CCOOUURRSSEE AACCTTIIVVIITTYY GGUUIIDDEE

TIME LOCATION TYPEINST SUBJECTMATTER

8:00 - 8:30 Classroom Discussion Introductions & Course Goals

8.30 - 9:30 Classroom Discussion/Video Kia Air conditioning Systems

or drawings on these materials to help youremember details

One of Kia’s main goal is to provide as muchindividual instruction as possible If you do notunderstand something in the classroom, askyour instructor to clarify the point

During hands-on practice sessions, you willoften be part of a working team You will only

learn from the experience if you actively

participate

This training course is an opportunity to learnadvanced skills successfully in a controlledenvironment under the guidance of a trainedKia instructor Have a good experience here,and return to your dealership with confidence

in your own abilities as a trained Kiaprofessional

COOUURRSSEE CCRREEDDIITTCourse credit will be granted by a Kia ServiceTraining Instructor when all of the criteria forcourse completion has been met

Because our technical training is

performance-based, hands-on practice will make up 65% of

your course credit Each Guided Practicemodule lists specific performance objectivesthat are the basis for scoring The instructorwill observe and evaluate your performance,coaching you when necessary

Additional factors that may affect this score aresafe and appropriate use of tools and

equipment and following written and verbalinstructions

Each Guided Practice Module is assigned arelative “point” value, depending on thedifficulty of the material

The final test, administered by the instructor, makes up 25% of your course credit

The instructor will evaluate the degree to whichyou contribute to discussions, offer your

experience, or simply ask questions aboutsomething you don’t understand Participationalso takes into account your professional

conduct, and working with teammates duringclassroom and shop practice activities This

counts for 10% of your course credit.

The sum of the above scores will determineyour course achievement performance

A minimum score of 80% is required for course credit.

NOTES _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

NOTES _

NOTES _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

KIIA A M MO OT TORS S A AM ME ER RIIC CA A,, IIN NC C

tions, specifications or procedures without prior notice or obligation.

Copyright © 2000 Kia Motors America, Inc Corporate Service Training

Department

4/00

S E E R R V V II C C E E T T R R A A II N N II N N G G

Kia Air Conditioning Systems

Student Learning Guide and Workbook

Appropriate service methods and proper repair dures are essential for the safe, reliable operation of allmotor vehicles as well as the personal safety of the indi-vidual doing the repair There are numerous variations

proce-in procedures, techniques, tools, and parts for servicproce-ingvehicles, as well as in the skill of the individual doing thework This module cannot possibly anticipate all suchvariations and provide advice or caution to each

Accordingly, anyone who departs from the instructionprovided in this module must first establish that hecompromises neither his personal safety nor the vehicleintegrity by his choice of methods, tools, or parts Thefollowing list contains general warnings that shouldalways be followed while working on a vehicle

• Always wear safety glasses for eye protection

• Use safety stands whenever a procedure requiresunderbody work

• Be sure ignition switch is always off unless wise specified by a procedure

other-• Set the parking brake when working on the vehicle

• Operate the engine only in a well ventilated area

• Keep clear of moving parts when engine is running

• To prevent serious burns, avoid contact with hotmetal parts such as the radiator, exhaust manifold,tail pipe, catalytic converter and muffler

• Do not smoke while working on a vehicle

Upon completion of this module, you will be familiar with the unique design characteristics that affect performance, diagnosis, and

maintenance of Kia air conditioning systems

Knowing how a Kia air conditioning system is designed to operate will help you diagnose Carefully read this material Study each

KIA AIR CONDITIONING

components that are used in Kia air conditioning systems and describe their function.

• Identify the function of each electrical signal used by the air conditioning system.

• Identify the various types of tests used to isolate Kia air conditioning malfunctions.

• Identify when and how to service the air conditioning system.

AC1-1

LEARNING OBJECTIVES

MODULE DIRECTIONS

THINGS YOU WILL NEED

illustration as you read the material Feel free to ask questions any time something is not clear Be sure to answer the SELF-TESTquestions at the end of the module

1998 or later Sephia and Sportage service manuals and ETMs

sure to view the Kia A/C Diagnosis Video.

• Conditions air coming

into the passenger

The air conditioning, or A/C system, is used

to condition the air entering the passenger compartment of the vehicle, or in some cases, the air that is already inside of the vehicle This includes cooling or heating, dehumidifying and filtering the air so that occupants are more comfortable at all times

Refrigeration System

The refrigeration system consists of the A/C compressor, the receiver/dryer, the evaporator, the condenser, the expansion valve, the dual pressure switch and the refrigerant hoses and lines

This sub-system circulates the R-134a refrigerant through the A/C system The refrigerant absorbs heat from the air entering the passenger compartment so that it can be released into the atmosphere by the cooling system

A/C Cooling System

The cooling system consists of any air intake components, the radiator, the radiator cooling fan, and the condenser cooling fan

Its purpose is to direct the flow of air through the condenser so that the heat absorbed by the refrigerant can be released into the atmosphere

Air Distribution System

The air distribution system consists of the Heater control assembly, the blower motor, and all of the ductwork, air doors, actuators, and mechanical linkage

This system controls the desired path, temperature, and volume of conditioned air entering or being re-circulated about the passenger compartment

- Dual pressure switch

- Refrigeration hoses and

lines

• Circulates R-134a to remove

heat from air entering

- Radiator cooling fan

- Condenser cooling fan

• Directs airflow through the

condenser so that the heat

absorbed by the refrigerant

can be released into the

• Consists of:

- Heater control assembly

- Blower motor

- All ductwork, air doors,

actuators, and mechanical

linkage.

• Controls the desired path,

temperature, and volume of

incoming or recirculated air.

AC1-6

In cold weather, the A/C removes moisture (humidity) so that the heater core can warm dry air This provides a more comfortable environment for the passengers, speeds up defogging the windows and helps keeps them from fogging up again.

On model year 2000 and later vehicles, the air conditioning will come on anytime “defrost” has been selected with the mode control

• A/C system is always

- Helps defroster keep

windows from fogging

• On model year 2000 and

later vehicles, the A/C

comes on whenever defrost

• Material applies to all Kia

Motors America vehicles.

• Exceptions noted, where

applicable.

AC1-7

PRINCIPLES OF REFRIGERATION

Before attempting to diagnose problems in any air conditioning (A/C) system, you must have a basic understanding of certain laws of physics, chemistry, and electricity

These include, but are not limited to: the behavior of heat, the behavior of refrigerants such as R-12 and R-134a, the properties

of liquids and gases, the effects of heat and pressure on liquids and gases, and the relationship between temperature and pressure

A basic understanding of these laws, along with an understanding of how air conditioning components are designed to function, will provide the skills necessary to make a quick and accurate diagnosis of an air conditioning malfunction

• A/C diagnosis requires

basic understanding of laws

of physics, chemistry, and

liquids and gases

- Effects of heat and

pressure on solids, liquids

2 The greater the difference in temperature, the faster heat flows

3 Heat will continue until both temperatures are equal

1 Heat always flows from an

area of higher temperature

to an area of lower

temperature.

2 The greater the difference

in temperature, the faster

heat flows.

3 Heat will continue until

both temperatures are

HEAT TRANSFER EXAMPLE #1

Take a look at the heat transfer example shown

in the illustration You can try this example at home to watch the heat transfer laws in action

If you would like to measure the results, place a thermometer in each glass

1 Fill one glass with hot water

and one glass with cool tap

water

2 Place an ice cube in each

glass.

3 The heat in the glass of hot

water will transfer to the

ice cube at a much higher

rate than heat in the glass

of cool water.

4 In either case, when the ice

cube has completely melted

all of the liquid in the glass

is the same temperature.

HEAT TRANSFER EXAMPLE #2

ENGINE COOLING SYSTEM

As the coolant passes through the radiator, heat from the coolant is transferred to the cooler outside air passing through the radiator fins.When coolant is allowed to flow through the heater core, heat from the coolant is transferred

to the cooler air flowing through the fins

of the heater core and into the passenger compartment

AC1-11

AC1-12

BEHAVIOR OF REFRIGERANTS

Refrigerants behave somewhat differently from

other liquids and gasses For example, engine

coolant is a liquid composed of water and

ethylene glycol Ideally, it remains a liquid as it

absorbs and releases heat

Refrigerants on the other hand, constantly

change states from a liquid to a vapor, then

back to a liquid as they travel through the A/C

system

PROPERTIES OF MATTER

Matter can exist in one of three states: solid,

liquid, or gas (vapor) Matter has the ability of

changing from one state to another, depending

on its temperature and the pressure placed

upon it

For example, an ice cube is a solid If we

place it in a hot frying pan on the stove, it will

change to a liquid (water), then as more heat is

absorbed, it will turn into a vapor (steam)

If the burner is turned off, the vaporizing

process will cease and the pan will contain only

liquid If the frying pan were placed in a freezer,

the liquid would change back to a solid

AC1-13

AC1-14

There is a law of physics that states: “A specific amount of heat is needed to change a liquid into a vapor”.

Notice in our water example, when the liquid absorbs enough heat to raise the temperature

to 212°F (100°C), the water starts turning into a vapor, or gas At atmospheric pressure, adding more heat will not raise the temperature, it will only create more vapor in a shorter period of time

When heat is removed from the water, it begins to turn back into a liquid This process produces “condensation” You can observe this process by watching the condensation build up

on the bathroom mirror after you have taken a shower

EFFECTS OF HEAT ON LIQUIDS AND GASES

PRESSURE-TEMPERATURE RELATIONSHIPS

The study of physics includes laws that describe the relationship between pressure and the temperature at which a liquid starts to turn into a vapor This is called its “boiling point”

The laws state the following:

1 If the pressure acting on a liquid is increased, the boiling point of the liquid also increases

2 Lowering the pressure acting on a liquid, lowers the boiling point of the liquid

In other words, water in a vacuum boils at a temperature that is less than 212°F (100°C) whereas the water in a pressure cooker or a sealed pressurized automotive cooling system boils at a higher temperature than 212°F (100°C)

• If the pressure acting on a

liquid is increased, the

boiling point of the liquid

also increases.

• Lowering the pressure

acting on a liquid lowers

the boiling point of the

liquid.

• These laws apply to all

liquids.

PRESSURE-TEMPERATURE RELATIONSHIP EXAMPLE

When the cooling system is sealed and under pressure, the boiling point is higher than 212°F (100°C) But when the pressure cap is removed, it immediately lowers the boiling point

of the coolant

AC1-16

AC1-17

A/C SYSTEM PRESSURE-TEMPERATURE RELATIONSHIP

The pressure developed by the A/C compressor raises the boiling point of the refrigerant A/C systems are designed to operate at just the right temperature for removing heat from the passenger compartment

There is a definite relationship between liquid refrigerants and their vapors When confined

in a sealed A/C system, an increase in the temperature of the refrigerant will always result

in an increase in pressure, even though the A/C compressor may not be operating at the time.The boiling point of R-134a at sea level is -16°F (-27°C) Since these temperatures are higher than those on an R-12 system, pressure readings also tend to be higher because of the pressure - temperature relationship

A/C Pressures are expressed as a positive gauge pressure in psi or kPa or a negative gauge pressure (vacuum) in inches of mercury.Now that you have reviewed the basics, let’s put it all together to see how an A/C system works

• Pressures developed by the

A/C compressor raises

boiling point of refrigerant.

• In a sealed A/C system, an

increase in temperature

always results in

an increase in pressure.

• The boiling point of

R-134a is higher than R-12;

pressure readings tend

gauge pressure in psi or

kPa or a negative gauge

pressure (vacuum) in

inches of mercury.

AC1-18

REFRIGERATION SYSTEM OPERATION

AC1-19

All Kia vehicles use Cycling Clutch, Thermostatic Expansion Valve (CCTXV) type air conditioning systems

In this type of system, the A/C compressor has

a fixed displacement The A/C compressor clutch is turned ON and OFF by the ECM or PCM based on inputs from the A/C thermostat

or thermocon, engine coolant temperature sensor, throttle position sensor, and the dual pressure switch

When the compressor is ON (clutch engaged), the A/C compressor draws in low pressure vaporized refrigerant from the evaporator through the suction line This vapor is then compressed and pumped to the condenser as a high pressure/high temperature vapor

As the refrigerant flows through the condenser, the air passing through the condenser fins from the condenser fan removes heat from the refrigerant, condensing it into a high pressure liquid

HEAT

REMOVED

Next, the refrigerant moves into the receiver/dryer where any moisture is removed by the Zeolite dessicant inside the unit.

From the receiver/dryer, the refrigerant moves through the expansion valve, where it expands into a low pressure, low temperature liquid which is routed to the evaporator

As the low temperature refrigerant passes through the evaporator core, it absorbs the heat from the passenger compartment and is changed (vaporized) into a low pressure, low temperature vapor to complete the cycle

This cycle is repeated as long as the compressor clutch is engaged and the compressor is running

Note: During this process, condensation

forms on the evaporator core This condensation drips off of the core and exits the vehicle through the evaporator drain tube.

AC1-20

REFRIGERATION SYSTEM OPERATION -Cont’d

HEAT ABSORBED

A/C ELECTRICAL CIRCUIT OPERATION

* This relay is called the A/C cut relay on Sportage

AIRCON 10A

Hot at all times

*A/C relay

Hot when ignition switch is ON

To blower control A/C

A/C Thermostat (thermocon)

Hot when ignition

When the ignition switch is in the ON position, battery voltage is applied to the coil on the control side of the A/C relay Battery voltage is also applied to the A/C switch through the 10-amp ACC fuse

With the A/C switch ON and the blower switch

in any position except OFF, voltage passes through the normally closed contacts of the A/C thermostat, or thermocon, and enters the ECM

as an A/C request signal

Operating parameters permitting, when the ECM receives the A/C request, it will apply

a ground to the control side of the A/C relay, allowing the relay contacts to close This allows battery voltage, which is always present at the load side of the A/C relay, to pass through its contacts to the coil in the A/C clutch When this happens, the A/C clutch engages and the A/C compressor begins to operate

AC1-21

The ECM is programmed to turn OFF the air conditioning system for brief periods of time

to allow the engine to start quicker, perform efficiently, and provide good driveability It also shuts OFF the air conditioning when the engine is under a load and engine coolant temperatures reach a certain temperature threshold This helps to prevent the engine from overheating

Before the ECM will allow the A/C clutch to engage or remain engaged, several conditions must be met The chart above lists the various conditions that will prevent the ECM from engaging the A/C clutch

A/C SYSTEM OPERATING PARAMETERS

AC1-22

Engine or A/C System Condition Reporting

Sensor Cut-off Period

Acceleration from idle CKP, MAF Approximately 2 seconds

Coolant temperature = 242°F ECTS Until ECT is below 240°F

Evaporator temp is below 35°F Thermocon Until evap temp is above 38°F

A/C system pressure = 28 psi or

less Dual pressure switch (Lo press) Until system has been repaired

A/C system pressure = 455 psi or

more Dual pressure switch (Hi press) Until system has been repaired

Note: The readings in this chart are approximate and will vary from model to model and

vehicle to vehicle Use the specifications shown in the service manual for your vehicle to determine the acceptable limits.

The A/C cooling sub-system is an important

part of the air conditioning system because it

removes heat from the refrigerant as it passes

through the condenser and it removes heat

from the engine coolant as it passes through

the radiator

The air intake system consists of the radiator

grille and various air dams, shrouds, and seals

Its job is to direct air flow from outside the

vehicle through the condenser and radiator fins

as shown in the illustration

Any front-end collision damage, missing

components, or obstructions in the condenser,

radiator, or between the two, will compromise

the effectiveness of the radiator and condenser

to remove heat

When the vehicle is stopped or moving slowly,

the condenser and radiator cooling fans help

the air intake system direct outside air through

the condenser and radiator

A/C COOLING SYSTEM OPERATION

AC1-23

The air distribution system controls the desired path, temperature, and volume of conditioned air entering or being re-circulated about the passenger compartment.

The evaporator core absorbs the heat in the passenger compartment so that cool outside

or recirculated air can exit through the selected outlets The heater core removes heat from the engine coolant so that warm air to heat the passenger compartment is available

The control panel allows an occupant to open

or close the air outlet doors, select a desired temperature, control the blower fan speed to obtain the desired volume of air, and turn the A/C system ON or OFF This is accomplished through a series of switches, actuators, and cables, depending on the model and year.Always refer to the owner’s manual and service manual for your vehicle to determine how the system is designed to function

AIR DISTRIBUTION SYSTEM OPERATION

AC1-24

The compressor assembly is the primary

moving part in the A/C system Its job is to

compress the refrigerant into a high pressure

vapor or gas and circulate it through the

system

The compressor is the “fixed displacement”

type because internal pressure controls make

variable displacement unnecessary

The A/C compressor is not repairable If it is

bad, it must be replaced.

COMPONENT OPERATION

A/C Compressor

AC1-25

A/C Compressor Clutch Assembly

The A/C compressor clutch is an

electro-magnetic assembly that connects the engine

crankshaft to the compressor through the drive

belt Operating parameters permitting, when

the A/C switch is turned to ON and the blower

switch is in any position except OFF, the ECM

will energize the A/C relay to engage the clutch

The clutch is a serviceable/replaceable

component and the air gap is adjustable using

selective shims

AC1-26

A/C Condenser

The condenser is mounted directly in front of the radiator It consists of a series of coils and fins that cool the refrigerant as air flow passes over them

The condenser is a serviceable/replaceable component

Condenser Fan

The condenser fan is located between the radiator grill and the condenser on Sportage and directly behind the radiator on Sephia Its job is to move outside air through the condenser so that the heat can be removed from the refrigerant This is extremely important when the vehicle is stopped or traveling slowly.The condenser fan is powered by battery voltage from the condenser fan relay on Sephia and the A/C relay on Sportage It should be running anytime the A/C compressor is in operation

AC1-27

AC1-28

Evaporator Core

The evaporator core is located inside the

Blower/Evaporator Assembly, near the blower

motor It consists of a series of coils and

fins that absorb the heat from the passenger

compartment as air flow passes over them

The evaporator core is a separate serviceable/

replaceable component

A drain hose, located at the bottom of the

evaporator case, allows condensation from the

evaporator core to drain out of the vehicle thus

preventing mildew, odors, and window fogging

Expansion Valve

Often called the thermal expansion valve,

the expansion valve is mounted directly to

the evaporator core Its purpose is to allow

high pressure liquid to expand as it enters

the evaporator It also controls, or meters,

the amount of refrigerant entering the system

to prevent the evaporator from flooding and

The position of the air temperature valve in the A/C module determines the warmth of the overall air flow that is sent into the passenger compartment.

The heater core is a serviceable/replaceable component

The receiver/dryer is a serviceable/replaceable component

AC1-31

AC1-32

Rubber hoses and metal pipes carry the refrigerant to the various A/C components The hoses are flexible to allow for movement of the engine and are designed for either low pressure

or high pressure use The pipes are made of metal and are rigid

All A/C hoses and lines are replaceable

Both service ports are the “quick disconnect”

type and are normally protected by blue primary seal caps that are marked “L” and “H” The ports are different sizes, the low pressure is M9

X 1.25 and the high pressure is M10 X 1.0

The low pressure port is on the low pressure hose and the high port pressure is on cooler pipe #1

Refrigerant Hoses and Lines

• 2 different size service ports

• Low pressure is located on

low pressure hose

• High pressure is located on

• Used to recover, evacuate,

recharge and test A/C

system

AC1-33

AC1-34

Heater Control Unit

The heater control unit provides a mounting platform for the air temperature control, mode control, fan speed control, air intake control, and the air conditioning ON/OFF switch

Over the years a variety of controls have been used on Sephia and Sportage The chart below illustrates the different controls that have been used

The heater control unit and several of its components are serviceable/replaceable

Blower Assembly

The blower assembly is located inside the evaporator assembly Its purpose is to draw in passenger compartment air and send it through the evaporator core and the heater core, if desired

It consists of a 12-volt electric motor and a

“squirrel cage” style fan blade

Blower speed is controlled by the fan control switch or lever and the blower resistor block.When the switch is OFF, the motor ground circuit is open Changing the fan switch from positions 1 through 3, causes the circuit resistance to decrease, allowing the fan to run faster In 4th speed, the electrical current path does not travel through any of the resistors in the resistor block, it travels directly to the blower motor

The fan control switch or lever, the resistor block, the blower motor, and the fan blade are all serviceable/replaceable parts

AC1-36

Air Conditioning Controls

Control ControlMode ControlIntake ControlFanSephia 1995.5 - 97 ON/OFF Button Twist/Elect. Twist/Cable Button/Elect. Twist/Elect.

Sportage 1995 - 97 ON/OFF Button Twist/Cable Slide/Cable Slide/Cable Slide/Elect.

AC1-35

Fresh/Recirculation Actuator

Depending on the vehicle model, the fresh/

recirculation actuator is either a 12-volt electric motor or mechanical linkage, located inside the evaporator assembly, and operated by the intake control switch

It allows an occupant to choose between fresh (outside) air or recirculated inside air by moving the fresh/recirculation door to the desired

position When the door has reached the desired position, the motor stops

The recirculation position is normally selected when a rapid increase or decrease in passenger compartment temperature is required

The fresh/recirculation actuator is a serviceable/

replaceable part

• Electric motor or

mechanical linkage located

inside the blower/ inside the blower/ inside the blower/

evaporator assembly

• Operated by the intake

control switch

• Allows occupant to choose

fresh outside or recirculated

Dual Pressure Switch

The dual pressure switch is mounted on top of the receiver dryer Its job is to signal the ECM/

PCM when A/C pressures go above or below specified limits by removing the ground from the A/C request circuit Section 62 of the service manual lists the high and low limits under “Other specifications”

The dual pressure switch is a serviceable/

replaceable component

A/C Thermocon

Often called the A/C thermostat, the thermocon

is located inside the evaporator assembly

Its purpose is to prevent the evaporator core from freezing up by not allowing A/C operation when the evaporator temperature is below about 35°F (1.5°C)

When the evaporator temperature is low the thermocon prevents battery voltage from reaching the ECM’s air conditioning request circuitry

When the evaporator temperature reaches approximately 38°F (0.5°C), the contacts in the thermocon close, allowing battery voltage from the A/C switch to reach the ECM

A/C Relay and A/C Cut Relay

The A/C relay and A/C cut relay (Sportage only) are located in the evaporator/blower assembly.They are controlled by the ECM and provide the battery voltage to the A/C clutch and the condenser fan relay as described in the illustration

When engine coolant temperature exceeds a pre-determined value, the ECM/PCM removes the ground from the control side of the A/C relay and A/C Cut Relay (Sportage only) to disengage the A/C compressor clutch and the condenser fan

• Located in evaporator

assembly

• Prevents evaporator from

freezing up in cold weather

• When evaporator is cold,

thermocon contacts are

open and no A/C operation

• When evaporator warms up,

thermocon contacts close

and A/C operates.

• A/C relay (Sephia) - supplies

power to A/C clutch and

condenser fan relay

• A/C relay (Sportage)

supplies power to

condenser fan

• A/C Cut relay (Sportage) -

supplies power to the A/C

clutch

• ECM/PCM removes the

ground from A/C relays

A/C SYSTEM DIAGNOSIS

Effective air conditioning diagnosis requires knowledge of how the system is supposed to operate in order to determine when it is not operating correctly

There are five basic steps for diagnosis and repair If you follow these steps in a systematic manner, you will usually find the cause of the problem the first time

VERIFY THE PROBLEM

Get an accurate description of the customer’s complaint Determine if the concern is a normal condition or a valid failure Sometimes a valid complaint exists, but if the system doesn’t work, you won’t have a lot of diagnostic information

on the repair order

Have the customer show you how they set the air conditioning controls If necessary, explain how to set the controls for maximum coolingNote the symptoms, but do not begin

disassembly or testing until you have narrowed down the problem area

• Verify the problem.

• Analyze the problem.

• Find the cause.

• Repair the problem.

• Check the repair.

AC1-41

you won’t have much

diagnostic information on

the RO

first hand with the

customer present

you how they set the A/C

controls

to set the A/C controls for

maximum cooling

testing until problem area

has been narrowed down

AC1-42

• Interview the customer

to find out more specific information

occur?

temperature and humidity when you noticed the problem?

overheating?

noises or odors?

AC1-43

Whats, Whens, and Hows

Before starting on a problem get as much information as possible about the problem Sometimes problems in one system may cause another system to operate erratically or not operate at all

It is best to interview the customer to find out more specific information such as:

When does the problem occur?

What was the outside temperature and humidity when you noticed the problem?

Was the engine overheating?

Were there any strange noises or odors?

ANALYZE THE PROBLEM

Once you have verified that a legitimate problem exists, you must determine whether the problem is related to some other obvious problem such as previous repairs, accident, or add on aftermarket equipment such as a front end cover or custom body panels

If you are satisfied that it is a system problem, it’s time to make some preliminary checks

A/C SYSTEM OPERATIONAL (QUICK) CHECK

While you are performing an operational check of the A/C system be sure to note the symptoms Do not begin disassembly or testing until you have narrowed down the problem area because the system may be operating as designed, but still may not meet the customer’s expectations

During the test, you will be checking for three things

1 Proper performance

2 Unusual noise

3 Unusual odors

Prepare the Vehicle

Prepare the vehicle for an A/C operational check by following the steps shown in the illustration

1 Roll down the windows.

2 Start the engine and warm

it to normal operating

temperature.

3 Turn all of the outlets

toward the rear of the

6 Select recirculation with

the air intake control.

7 Set the fan speed to the

maximum position.

8 Turn on the A/C switch.

or testing

but still may not meet