Wheel Disc and Hub Assembly Removal and Installation
Troubleshooting
Troubleshooting
Symptom Table
Before replacing or repairing air conditioning components, first determine whether the malfunction is related to refrigerant charge, airflow, or the compressor. Use the table below to help find the cause of the problem. The numbers indicate the priority of the probable cause. Check each part in order. If necessary, replace these parts. After the malfunction is eliminated, check the entire system to make sure it operates satisfactorily.
Symptom
Suspect area
No Fan Operation
1. Blower Fuse
2. Blower Motor
3. Power MOSFET
4. Blower Speed Switch
5. Wire Harness
No Air Temperature Control
1. Engine Coolant Level
2. Heater Control Unit
Compressor Does Not Operate
1. Cooling Capacity
2. Air Conditioner Fuse
3. Magnetic Clutch
4. Compressor
5. A/C Pressure Sensor
6. A/C Switch
7. Evaporator Temperature Sensor
8. Wiring Harness
Does not cool well
1. Cooling Capacity
2. Refrigerant Pressure
3. Drive Belt.
4. Magnetic Clutch
5. Compressor
6. A/C Pressure Sensor
7. Evaporator Temperature Sensor
8. A/C Switch
9. Heater Control Unit
10. Wire Harness
Insufficient Cooling
1. Cooling Capacity
2. Drive Belt
3. Magnetic Clutch
4. Compressor
5. Condenser
6. Expansion Valve
7. Evaporator
8. Refrigerant Lines
9. A/C Pressure Sensor
10. Heater Control Unit
Engine Does Not Idle Well with A/C On
1. Engine ECM
2. Wiring Harness
No Air Flow Control
1. Heater Control Unit
No Mode Control
1. Heater Control Unit
Cooling Fan Does Not Operate
1. Cooling Fan Fuse
2. Blower Motor
3. Engine ECM
4. Wiring Harness
Air Conditioning
General Safety Information and Precautions
Instructions
When Handling Refrigerant
R-134a liquid refrigerant is very volatile. A drop on your skin may cause local frostbite. Always wear gloves when handling refrigerant.
It is standard practice to wear safety goggles or eye protection, and gloves to protect your hands. If refrigerant gets into your eyes, flush them immediately with clean water.
The R-134a container is under high pressure. Never leave it in a hot place, and make sure the storage temperature is below 52 °C.
An electronic leak detector should be used to check the system for refrigerant leaks. Be aware that R-134a produces phosgene, a highly toxic gas, when it comes into contact with a flame.
Use only the lubricant recommended for R-134a systems. If lubricants other than those recommended are used, system failure may occur.
PAG lubricant absorbs moisture from the atmosphere very quickly, so the following precautions must be observed:
When removing refrigerant components from the vehicle, immediately cap the components to prevent moisture from entering.
When installing refrigerant components on the vehicle, do not remove the cap until the components are ready to be connected.
Complete the connection of all refrigerant pipes and hoses immediately to prevent moisture from entering the air conditioning system.
Use only recommended lubricant taken from a sealed container.
In case of accidental discharge of the system, ventilate the work area before resuming work.
Never open or loosen a connection until the system has been discharged.
Immediately cap or plug open component fittings to prevent moisture or dirt from entering.
Do not remove the sealing caps from a replacement component until it is ready for installation.
Before connecting an open fitting, always install a new O-ring. Coat the fitting and seal it with refrigerant oil before making the connection.
When replacing air conditioning system parts, when installing connection parts, Flange with Guide Pin: Check the new O-ring for damage (use only the specified one) and lubricate it with compressor oil. Tighten the nut to the specified torque.Handling Pipes and Fittings: The internal parts of the refrigeration system remain chemically stable as long as clean refrigerant without moisture and refrigerant oil are used. Abnormal amounts of dirt, moisture, or air can disrupt chemical stability and cause problems or serious damage. The following precautions must be observed.
When it is necessary to open the refrigeration system, have everything you need to service the system ready so that the system is not left open longer than necessary.
Cap or plug all lines and fittings as soon as they are opened to prevent dirt and moisture from entering.
All lines and components in the parts stock must remain capped or sealed until they are ready for use.
Never attempt to bend pre-formed lines to make them fit. Use the correct line for the installation you are servicing.
All tools, including the refrigerant dispensing manifold, gauge manifold and charging hoses, must be kept clean and dry.
Description and Operation
Refrigeration Cycle
Repair Procedures
Refrigerant System Service Basics
Refrigerant Recovery: Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 for removing HFC-134a (R-134a) from the air conditioning system.In case of accidental system discharge, ventilate the work area before resuming work. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Connect the R-134a refrigerant recovery/recycling/charging unit (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, according to the equipment manufacturer's instructions.
Measure the amount of refrigerant oil removed from the air conditioning system after the recovery process is complete. Be sure to add the same amount of new refrigerant oil back into the air conditioning system before charging.
System Evacuation: Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 for removing HFC-134a (R-134a) from the air conditioning system.In case of accidental system discharge, ventilate the work area before resuming work. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
When the air conditioning system has been opened to the atmosphere, such as during installation or repair, it must be evacuated using the R-134a refrigerant recovery/recycling/charging unit. (If the system has been open for several days, the receiver/drier should be replaced, and the system must be evacuated for several hours.)
Connect the R-134a refrigerant recovery/recycling/charging unit (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, according to the equipment manufacturer's instructions.
If the low pressure does not reach 93.3 kPa (700 mmHg, 27.6 inHg) after 10 minutes, there is likely a leak in the system. Partially charge the system and check for leaks (refer to Leak Check).
Remove the low-pressure valve from the low-pressure service port.
System Charging: Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 for removing HFC-134a (R-134a) from the air conditioning system.In case of accidental system discharge, ventilate the work area before resuming work. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Connect the R-134a refrigerant recovery/recycling/charging unit (A) to the high-pressure service port (B), as shown, according to the equipment manufacturer's instructions.
Add the same amount of new refrigerant oil to the system as was removed during recovery. Use only the specified refrigerant oil. Charge the system with 13.05 ± 0.88 oz. (370 ± 25 g) of R-134a refrigerant. Do not overcharge the system, as the compressor will be damaged.
Refrigerant Leak Test: Always perform a leak test using an electronic leak detector whenever a refrigerant leak is suspected, and when performing service operations that involve disassembling, loosening, or connecting fittings.If a refrigerant leak is detected, perform the following steps:
Check the torque on the connection fittings and, if they are too loose, tighten to the correct torque. Check for gas leakage using a leak detector (A).
If the leak continues even after tightening the fitting, drain the refrigerant from the system, disconnect the fittings, and inspect their sealing surfaces for damage. Always replace, even if the damage is minor.
Check the compressor oil and add oil if necessary.
Charge the system and recheck for refrigerant leaks. If no leaks are found, evacuate and recharge the system again.
Components and Component Location
Component Location Index
Engine Compartment
1. Compressor 2. A/C pressure sensor 3. Service port (high)
4. Service port (low) 5. Expansion valve
Interior
1. Photo sensor 2. Heater and A/C control (manual) 3. Heater and A/C control (FATC)
4. Heater and blower 5. Evaporator sensor
Compressor Oil
Repair Procedures
Oil Specification
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.
Compressor oil (PAG) depends on the compressor model. Be sure to use the oil specified for the compressor model.
The oil must not contain moisture, dust, metal powder, or the like.
Do not mix with other oil.
The water content of the oil increases when it contacts air. After use, immediately isolate the oil from air. (HFC-134a compressor oil absorbs moisture very easily.)
Compressor oil must be stored in steel containers, not plastic.
Handling Oil: Checking Compressor Oil. The oil used to lubricate the compressor circulates with the refrigerant. Whenever any system component is replaced or a large refrigerant leak occurs, add oil to maintain the original oil quantity.
Total oil quantity in system PAG oil: 100 ± 10 g
Oil Return Operation: There is a close relationship between oil and refrigerant. During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the oil quantity in the system or replacing any system component, the compressor must be run beforehand for the oil return operation. The procedure is as follows:
Open all doors and the hood.
Start the engine and set the air conditioner switch to "ON", and set the blower fan control knob to the maximum position.
Operate the compressor for more than 20 minutes at 800 to 1000 rpm to stabilize the system.
Stop the engine.
Component Replacement: When replacing system components, add the following quantity of oil to the components being installed.
Components to be installed
Oil Capacity
Evaporator
50 g (1.70 fl oz)
Condenser
30 g (1.02 fl oz)
Receiver/Drier
30 g (1.02 fl oz)
Refrigerant Line (One Piece)
10 g (0.34 fl oz)
When replacing the compressor, 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: Specified volume - volume drained from removed compressor = volume to drain from new compressor.
Refrigerant Line
Components and Component Location
Component Location
Repair Procedures
Replacement
Discharge the refrigerant from the refrigerant system.
Replace the faulty pipe or hose.
Tighten the bolt or nut connection to the specified torque.
Part tightened
N·m
kgf·m
lbf·ft
Condenser - Outlet Hose
6,8 - 10,7
0,7 - 1,1
5,6 - 7,9
Condenser - Liquid Tube
Compressor - Discharge Hose
18,6 - 27,4
1,9 - 2,8
13,7 - 20,2
Compressor - Suction Hose
Expansion Valve - Evaporator
7,8 - 11,7
0,8 - 1,2
5,7 - 8,6
Evacuate the air conditioning system and charge it with refrigerant.
Specified quantity: 370 ± 25 g (13.0 ± 0.88 oz).
Check for refrigerant leaks. Using a gas leak detector, check for refrigerant leakage.
Check the air conditioner operation.
Compressor
Components and Component Location
Components [5VSe09]
1. Bolt 2. Disc and hub assembly 3. Clearance shim (spacer) 4. Snap ring
5. Pulley 6. Snap ring 7. Field coil 8. Compressor assembly
Components [5CS09]
1. Bolt 2. Disc and hub assembly 3. Clearance shim (spacer) 4. Snap ring 5. Pulley
6. Snap ring 7. Field coil 8. Compressor assembly 9. Manifold
Repair Procedures
Removal
If the compressor is operating at its limit, start the engine at idle, let the air conditioning run for several minutes, then turn the engine off.
Disconnect the negative battery cable.
Recover the refrigerant using a recovery/recharging station.
Remove the drive belt. G 1.0 MPI-KAPPA (refer to Engine Mechanical System - Drive Belt) G 1.2 MPI-GAMMA (refer to Engine Mechanical System - Drive Belt) F 1.0 KAPPA FFV (refer to Engine Mechanical System - Drive Belt) G 1.0 T-GDI KAPPA (refer to Engine Mechanical System - Drive Belt)
Remove the intercooler. [G 1.0 T-GDI KAPPA] G 1.0 T-GDI KAPPA (refer to Engine Mechanical System - Intercooler)
Loosen the bolts, then disconnect the discharge line (A) and suction line (B) from the compressor.
Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B). [5VSe09] [5VS09]
Installation
Check the length of the compressor mounting bolts, then tighten them in the order A→B→C→D.
Tightening torque: 20.0 – 33 N·m
[5VSe09] [5CS09]
Install in the reverse order of removal, and pay attention to the following items.
When installing a new compressor, drain all refrigerant oil from the removed compressor and measure its volume. Subtract the volume of drained oil from the original capacity to calculate the amount of compressor oil to be drained from the new compressor (through the suction port).
Replace the O-rings with new ones at each fitting and apply a thin coat of refrigerant oil before installation. Be sure to use the correct O-rings for R-134a to prevent leaks.
To avoid contamination, do not return spilled oil to the container, and never mix it with other refrigerant oils.
Immediately after use, close the container with its cap to prevent moisture absorption.
Inspection
Inspect the galvanic parts of the retainer and hub assembly (A) for discoloration, peeling, or other damage. If damaged, replace the assembly.
Check the pulley bearing play (B) and the resistance when turning the pulley by hand. Replace the pulley with a new one if it is noisy or has excessive play/drag.
Check the operation of the magnetic clutch. Connect the compressor-side terminal to the battery (+) terminal and ground the battery (-) terminal to the compressor body. Check the clutch operating noise to determine its condition.
Disassembly
Remove the front left wheel (A) from the hub.
Remove the engine cover. G 1.0 MPI-KAPPA (refer to Engine Mechanical System - Under Engine Cover) G 1.2 MPI-GAMMA (refer to Engine Mechanical System - Under Engine Cover) F 1.0 KAPPA FFV (refer to Engine Mechanical System - Under Engine Cover) G 1.0 T-GDI KAPPA (refer to Engine Mechanical System - Under Engine Cover)
Remove the front wheel guard. (Refer to Body - "Front Wheel Guard")
Remove the center bolt (A) while holding the disc and hub assembly with SST (09977-29000).
Tightening torque: 10~15 N·m
Remove the disc and hub assembly (A) and the shim (clearance washer), taking care not to lose the shims (B).
Loosen the drive belt. G 1.0 MPI-KAPPA (refer to Engine Mechanical System - Drive Belt) G 1.2 MPI-GAMMA (refer to Engine Mechanical System - Drive Belt) F 1.0 KAPPA FFV (refer to Engine Mechanical System - Drive Belt) G 1.0 T-GDI KAPPA (refer to Engine Mechanical System - Drive Belt)
Disconnect the snap ring (A) and remove the pulley (B).
Remove the snap ring (A), then remove the field coil (B). Be careful not to damage the coil and compressor.
Reassemble the compressor clutch in the reverse order of disassembly, and pay attention to the following items:
Clean the sliding surfaces of the pulley and compressor with a non-oil solvent.
Install new snap rings and make sure they are fully seated in the groove.
Make sure the pulley rotates smoothly after reassembly.
Condenser
Components and Component Location
Component Location
1. Condenser
Repair Procedures
Removal
Recover the refrigerant using a recovery/recycling/charging station.
Disconnect the negative (-) battery terminal.
Remove the front bumper. (Refer to Body - Front Bumper Assembly)
Remove the air damper (A) after loosening the mounting.
Remove the discharge line (A) and liquid line (B) from the condenser after loosening the nuts.
Tightening torque: 6.8–10.7 N·m
Remove the side air guard (A).
Remove the condenser assembly (A).
Install in the reverse order of removal.
Receiver-Drier
Repair Procedures
Replacement
Remove the condenser, then remove the lower cover (B) from the condenser using the L-shaped wrench (A).
Tightening Torque: 9.8–14.7 N·m
Remove the desiccant (A) from the condenser using long-nose pliers. Check the desiccant and the lower cover filter for clogging.
Apply compressor oil along the O-rings and threads of the new lower cap.
Install the new desiccant into the receiver-drier. The desiccant must be sealed in vacuum until it is exposed to air for use.
Install the new lower cap on the condenser.
A/C Pressure Sensor
Components and Component Location
Component Location
1. Air Conditioning Pressure Sensor
Description and Operation
Description
The air conditioning pressure sensor converts the high-pressure line pressure value into a voltage value. Based on the converted voltage value, the engine ECU controls the cooling fan by switching it to high or low speed. The engine ECU stops compressor operation when the refrigerant line temperature is too high or too low to optimize the air conditioning system.
Repair Procedures
Inspection
Measure the high-pressure line pressure by measuring the output voltage between terminals No. 1 and No. 2.
Check whether the voltage value is within the normal value or not.
Voltage = 0.00878835 * Pressure (PSIG) + 0.5
If the measured voltage value does not meet the specification, replace the A/C pressure sensor.
Replacement
Disconnect the negative (-) battery terminal.
Recover the refrigerant using a recovery/recharging station.
Disconnect the air conditioner pressure sensor connector (A).
Remove the A/C pressure sensor (B).
Install in the reverse order of removal.
Evaporator Temperature Sensor
Description and Operation
Description
The evaporator temperature sensor detects the evaporator core temperature and cuts power to the compressor relay to prevent the evaporator from freezing due to excessive cooling.
Repair Procedures
Inspection
Ignition switch OFF.
Disconnect the evaporator temperature sensor.
Using a multimeter, measure the resistance between terminals "1" and "2" of the evaporator temperature sensor.Specification
Evaporator core temperature [°C(°F)]
Resistance [kΩ]
-20
70.04
-10
43,35
0
27,62
10
18.07
20
12.11
30
8.30
40
5,81
50
4.15
Replacement
Disconnect the negative (-) battery terminal.
Remove the evaporator temperature sensor (B) by turning it 90° counterclockwise and pulling it out.
Install in the reverse order of removal.
Photo Sensor
Description and Operation
Description
The photo sensor is located in the center of the defrost nozzle. The photo sensor contains a photovoltaic (sunlight-sensitive) diode. Solar radiation received by its light-receiving part generates an electromotive force proportional to the amount of radiation received, which is transmitted to the automatic temperature control module to compensate for solar radiation.
Repair Procedures
Inspection
Ignition switch ON
Using a scan tool.
Direct intense light onto the photo sensor using a lamp, and check the change in output voltage.
The voltage will increase with more intense light and decrease with less intense light.
1. Auto light sensor signal 2. Auto light sensor ground 3. Passenger photo sensor 4. LED battery (+)
5. LED signal 6. Driver photo sensor (-) 7. Photo sensor (+5V) 8. Auto light sensor (+5V)
Replacement
Disconnect the negative (-) battery terminal.
Using a flat-blade screwdriver (-), remove the photo sensor (A) from the center of the defrost nozzle.
Install in the reverse order of removal.
Ambient Sensor
Description and Operation
Description
The ambient temperature sensor is located in front of the condenser and detects the outside air temperature. It is a negative temperature coefficient (NTC) thermistor. Resistance increases at lower temperatures and decreases at higher temperatures.
The sensor output is used to control discharge temperature, temperature-control door, blower motor speed, mode blend control and cabin humidity control.
Repair Procedures
Inspection
Ignition switch OFF
Disconnect the ambient temperature sensor.
Check the resistance of the ambient temperature sensor between terminals 1 and 2 and verify that it changes as the ambient temperature changes.Specification
Ambient Temperature [°C(°F)]
Resistance between terminals 1 and 2 (kΩ)
-30(-22)
507
-20(-4)
284,5
-10(14)
164,2
0 (32)
97,5
10 (50)
59,6
20 (68)
37,46
30(86)
24.18
40(104)
16
50(122)
18,83
Replacement
Disconnect the negative (-) battery terminal.
Remove the engine cover. G 1.0 MPI-KAPPA (refer to Engine Mechanical System - Under Engine Cover) G 1.2 MPI-GAMMA (refer to Engine Mechanical System - Under Engine Cover) F 1.0 KAPPA FFV (refer to Engine Mechanical System - Under Engine Cover) G 1.0 T-GDI KAPPA (refer to Engine Mechanical System - Under Engine Cover)
Disconnect the connector (A) and remove the ambient temperature sensor (B).
Install in the reverse order of removal.
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