1. SPECIFICATIONS 01-2

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1 SPECIFICATIONS Description Specification Heater Core size (mm²) 200 x x 25 Capacity (kcal/h) 4,700 Evaporator Core size (mm²) x x 60 Capacity (kcal/h) 4,700 Blower Supplied power (W) % Max (at12v) Fan speed (rpm) 2900 ± 200 Supply voltage (V) 12.0 PTC Supply power (W) 900~1,050 Compressor Capacity (cc/rev) 170 Diameter of pulley (mm) 120 Max. speed (rpm) 8,000 Supply voltage (V) 12.0 Power consumption (A) 2.2 Discharge pressure (kgf/cm²g) 8~10 Power transistor Supply voltage (V) 12.0 Operating temperature ( ) -30 ~60 Resistance Hi-Low (Ω) 2.0 Ω ± 10% Hi-ML (Ω) 0.9 Ω ± 10% Hi-MH (Ω) 0.4 Ω ± 10%

2 COMPONENTS 1. Blower and evaporator assembly 2. Actuator assembly - Intake 3. Air filter assembly 4. Cover - Air filter 5. Blower motor assembly 6. Resistor 7. Expansion valve assembly 9. Wiring assembly - Heater & evaporator 10. Heater assembly 11. Actuator assembly - Temperature 12. Actuator assembly - Mode 15. Heater assembly - PTC 20. Control assembly - Heater and A/C control 21. Bulb 22. Insert assembly - Ventilation 23. Sensor assembly - Humid and Incar 24. Sensor assembly - Intake

3 Condenser assembly 2. Compressor assembly - A/C 3. Hose assembly - Discharge 4. O-ring 5. O-ring 7. O-ring 8. O-ring 9. Hose assembly - Heater inlet 10. Hose assembly - Heater outlet 11. Pipe assembly - Joint 12. O-ring 13. O-ring 14. Pipe assembly - Liquid No Pipe assembly - Liquid No O-ring 17. Pipe assembly - Liquid No Hose assembly - Liquid 19. Receiver drier and bracket assembly 20. Nut 21. Nut 22. Bracket assembly - A/C compressor 23. Bolt 25. Bracket assembly - A/C compressor sub 26. Bolt 27. Hose - Drain 30. Sensor assembly - Receiver drier 50. Cap - Charge valve

4 Duct assembly - Console front 4. Screw 8. Duct assembly - Console rear 9. Duct assembly - Console foot 10. Duct assembly - Foot

5 TROUBLESHOOTING 1) Overview The FATC has a self-diagnosis function that can diagnose the system by itself. Before checking a component, be sure to check the fault code by using the self-diagnosis function. The selfdiagnosis consists of 6 steps. The temperature control dial (step 2 to 5) and fan speed dial (step 6) are used to enter each step of the self-diagnosis. The 6 steps of the self-diagnosis are: Step 1 - The VFD and all LED segments are checked for proper illumination. Step 2 - The sensors and air mix door are checked for proper operation. Step 3 - The position and condition of the air source door and mode door are checked. Step 4 - The actuator door position, fan speed and compressor operation are checked. Pressing the defroster switch after entering step 4 changes the diagnosis mode as follows: 41 -> 42 -> 43 -> 44 -> 45 -> 46 -> 41.

6810-01 01-7 Step 5 - You can check that the temperature value from each temperature sensor is displayed properly in this step.

6 Step 5 - You can check that the temperature value from each temperature sensor is displayed properly in this step. Pressing the defroster switch changes the temperature value that appears on the display in the order as follows: 51 Ambient temperature display Interior temperature display Intake air temperature display Ambient temperature sensor Interior temperature sensor Intake air temperature sensor Step 6 - To enter the step 6 from 5, turn the fan speed dial lightly toward the right not using the temperature control dial. In this step, you can decrease or increase by up to 3 degrees from the temperature set on the A/C controller. 2) Self-diagnosis step (1) Step 1 Turn the ignition ON and press the OFF switch for 5 sec. or more within 10 sec. Then the first step of the self-diagnosis is started as shown in the below figure. 2. Display for checking VFD and all LED segments 1. Press OFF switch for 5 sec. or more

), the one digit number between 0 and 8 is added behind "2". "20" means there is no fault code. For the meaning of the rest of the numbers, refer to the description below. 1.

7 01-8 (2) Step 2 The sensors and air mix door are checked for proper operation in this step. When the step 2 is started, the number "2", which indicates that the system is in the step 2, apprears on the display and the check for sensors is performed. Once the check is done (for 10 to 20 sec.), the one digit number between 0 and 8 is added behind "2". "20" means there is no fault code. For the meaning of the rest of the numbers, refer to the description below. 1. Turn temperature dial lightly toward right to enter step 2 10 to 20 sec. 2. System starts sensor 3. Fault code for sensor check after "2" is appears and blinks displayed If "-" is displayed before "2", it means that the sensor for that flashing fault code has a short circuit. Ambient temperature sensor short circuited Fault code no. 1 (ambient temperature sensor) blinks twice Fault code no. 5 (sun sensor) blinks twice (fault codes appears sequentially) Refer to the following table for the meaning of the fault code.

8 (3) Step 3 In this step, you can check the position and condition of the air source door and mode door. To start step 3, turn the temperature control dial lightly toward the right and confirm that the number 3 appears on the display. It takes several tens of seconds to finish the check. If there is no fault code, "30" is displayed. And if there is a malfunction, the corresponding fault code is added as described in the step Turn temperature dial lightly toward right to enter step 3 Refer to the following table for the meaning of the fault code. 2. System starts 3. Fault code for sensor check after sensor appears "3" is displayed and blinks (30 is displayed when there is no fault)

9 01-10 (4) Step 4 In this step, the door position of each actuator, fan speed and operation of the compressor are checked. To enter this step, turn the temperature dial to the right in the step 3. The number, "41", appears on the display as soon as the step 4 is started. Press the defroster switch to change the diagnosis mode. 1. Turn temperature dial lightly toward right to enter step 4 Press Press Press Press Press Press Below table describes the detailed diagnosis items performed for each number. Check the corresponding component for proper operation according to the table. The voltage values listed in the table are the output voltage to operate the blower motor. The higher the voltage, the faster the fan speed is.

6810-01 01-11 (5) Step 5 In this step, the system checks the temperature sensors used to control the A/C. To enter this step, turn the temperature dial to the right in the step 4.

10 (5) Step 5 In this step, the system checks the temperature sensors used to control the A/C. To enter this step, turn the temperature dial to the right in the step 4. The ambient temperature appears on the display first and the interior temperature appears next and the intake air temperature last. The display changes the temperature value each time the defroster switch is pressed. 1. Turn temperature dial lightly toward right to enter step 5 Press Press Press Ambient temperature display Interior temperature display Intake air temperature display (6) Step 6 You can increase or decrease by up to 3 degrees from the set temperature. When entering the step 6 from 5, turn the fan speed dial. 2. Turn temperature control dial to adjust temperature 1. Turn fan speed dial to enter step 6 Step 6 starts Decrease by up to 3 degrees Increase by up to 3 degrees

11 01-12 (7) How to end self-diagnosis Turn the AUTO switch ON or turn OFF the ignition key. (8) When A/C system is faulty (Initial auto-diagnosis) The fault code for the faulty sensor is not displayed. Therefore you should start the self-diagnosis to check the system.

12 ) Trouble Diagnosis (1) Duct Temperature Sensor If the fault code for the duct temperature sensor (DTC 3) appears on the display, check the sensor as follows: A. Remove the duct temperature sensor and measure the resistance between the terminals of the connector (specification: approx. 2.2 kw at 25 ). If the resistance value is extremely high or low, replace the duct temperature sensor. B. If the result is not as specified, replace the duct temperature sensor. If the result is as specified, proceed to the next step. C. Turn the ignition switch to ON position and measure the voltage between the connector of the FATC controller and the duct temperature sensor (specification: approx. 2 V at 25 ). D. If the voltage cannot be measured, check the wiring for open circuit. If the result is as specified, replace the FATC controller. (2) Power Transistor If the fault code for the power transistor (DTC 6) is displayed, check as follows: A. Turn the ignition switch to ON position. B. Measure the voltage between the terminals of the blower motor while changing the fan speed from the lowest level to the highest level. C. The specified voltage value in each stage: D. If the voltage is out of specified value, check the wiring for open circuit. If the wiring is intact, replace the power transistor. (3) Thermo AMP Sensor (Intake Air Sensor) If the A/C is not turned on, check as follows: A. Remove the thermo AMP and measure the voltage between the terminals no. 1 and 2 of the connector. B. Check if the voltage is approx. 12 V when the output is ON and 0 V when the output is OFF. C. If the voltage value is not as specified, replace the thermo AMP. If the value is as specified, proceed to the next step. D. Turn the ignition switch to ON position and turn on the A/C by pressing the A/C button. And measure the voltage between the terminals A12 and A11 of the FATC controller connector (specification: approx. 12 V). E. If the voltage cannot be measured, check the wiring for open circuit. If the result is not as specified, replace the thermo AMP.

13 01-14 (4) Sun-load sensor A. Remove the sun-load sensor and measure the current between the terminals with the sensor exposed to direct sunlight. B. Measure the current again in the shade. If this value is lower than the measured value in the sunlight, the sensor is intact. C. Turn the ignition switch to the "ON" position. D. Measure the voltage between the terminals of the sun sensor at the FATC connector. (approx. 2.5 V under sunlight and approx. 4.8 V under shade) E. If the voltage cannot be measured, check the wiring for open circuit. If the result is not as specified, replace the FATC controller.

14 SYSTEM LAYOUT (EXTERIOR) Receiver drier A/C compressor Line and port Ambient temperature sensor A/C condenser Electric fan

15 SYSTEM LAYOUT (INTERIOR) Sun-load sensor A/C controller A/C Module assembly Mode door actuator Air mix door actuator

16 PTC Air source mode actuator Duct temperature sensor Thermo AMP Power transistor Blower motor assembly A/C filter

17 VENTILATION SYSTEM 1) Vent Ports Location - Interior 2) Configuration of Air Duct

6810-01 01-19 4. A/C MODULE 1) Components 1. Mode door actuator 2.

Air source door actuator 6. A/C antibacterial filter 7. Blower motor 8.

18 A/C MODULE 1) Components 1. Mode door actuator 2. PTC heater assembly 3. Duct temperature sensor 4. Air mix door actuator 5. Air source door actuator 6. A/C antibacterial filter 7. Blower motor 8. Power transistor 9. Thermo AMP 10. Mode door 11. Heater core 12. Air mix door 13. Evaporator 14. Air source door

01-20 2) Configuration Air source door case A/C filter Blower unit (upper) case Air source door actuator Blower motor assembly Blower unit (lower) case Evaporator Duct temperature sensor

19 ) Configuration Air source door case A/C filter Blower unit (upper) case Air source door actuator Blower motor assembly Blower unit (lower) case Evaporator Duct temperature sensor Thermo AMP Power Transistor A/C cable assembly Heater unit (right) case Heater core Air mix door actuator Lower duct Mode door Heater unit (left) case Mode door actuator Mode door link assembly

20 ) Wiring Layout Duct temperature sensor Mode door actuator Air source door actuator Power transistor Air mix door actuator Main wiring connector Interior temperature sensor Thermo AMP A/C controller unit Blower motor

22 A/C INPUT/OUTPUT DIAGRAM Below diagram shows the input/output mapping between the components of FATC A/C and A/C controller briefly. A/C compressor control by engine ECU In case of current vehicle models, the system turns ON or OFF the compressor switch according to the refrigerant pressure, ambient temperature and condenser temperature to protect the A/C circuits. However, for the vehicles equipped with DI engine, the engine ECU turns off the A/C compressor under below conditions, including those above. 1. Coolant temperature: 20 or less 2. Coolant temperature: 115 or more 3. For approx. 4 sec. after starting the engine 4. Engine speed: 650 rpm or less 5. Engine speed: 4,500 rpm or more 6. During abrupt acceleration for the vehicle equipped with manual transmission

23 A/C COOLING CYCLE 1) System Flow - "Compression -> Condensation -> Expansion -> Evaporation" 2) Functions (1) Compressor - - Condition: Gas Function: Circulates the refrigerant and increases the pressure and temperature for easier evaporation. (2) Condenser - Condition: Gas/Liquid - Function: Cools and condenses the refrigerant by using ambient air to liquefy it under high pressure. (3) Receiver drier - - Condition: Gas/Liquid Function: Keeps the refrigerant free from moisture by separating/collecting the moisture from it. (4) Expansion valve - - Condition: Liquid/Liquefied gas Function: Performs adiabatic expansion and flow control for easier evaporation. (5) Evaporator - - Condition: Liquefied gas/gas Function: Cools the air by absorbing the heat from the air around the evaporator.

24 ) Description for Each Cycle (1) Compression - The evaporated refrigerant in the evaporator enters to the compressor. And the refrigerant gas is compressed until it can be liquefied at ambient temperature. - Thus, the low refrigerant pressure is maintained so that the liquid refrigerant can be evaporated actively at low temperature (around 0 ). (2) Condensation - The high pressure and high temperature gas (refrigerant) from the compressor is cooled down by the fresh air entered into the condenser. Then, this gas is converted to liquid and collected in the receiver drier. The heat generated from the high pressure refrigerant is dissipated to the ambient air, and it is called "heat of condensation". - The heat of condensation is the summation of the heat of vaporization (heat that the refrigerant absorbs from the inside of the vehicle) and the calorific value converted from the amount of work which is needed to compress. (3) Expansion - The liquid refrigerant lowers the pressure making its evaporation easily accomplished. This process (lowering the pressure to the level at which evaporation easily takes place before the liquid refrigerant is sent to the evaporator) is called "Adiabatic Expansion". - During adiabatic expansion, the expansion valve lowers the pressure of the refrigerant and determines the correct amount of refrigerant going into the air conditioning evaporator. That is, the amount of heat, which is needed to stop the evaporation, is determined according to the cooling load. The expansion valve detects this and regulates the amount of the refrigerant exactly. (4) Evaporator - The refrigerant is converted from liquid to gas in the evaporator. (The refrigerant in the form of fog in the evaporator is vaporized actively) - At this time the refrigerant, in the form of liquid, absorbs the heat in the air which is need for evaporation (latent heat) and is cooled down. Then the blower blows the cooled air inside the vehicle to lower the temperature. - There are liquid refrigerant from the expansion valve and evaporated refrigerant in the evaporator. - The evaporation temperature can be predicted from the evaporation pressure (i.e. relationship between saturation pressure and saturation temperature). - It is important to keep the pressure inside the evaporator low, so that the refrigerant is evaporated at low temperature to make sure the completely evaporated refrigerant is entered into the compressor.

25 A/C CIRCUIT DIAGRAM 1) A/C (AUTO): PWM Motor, Compressor, Air Mix Motor, Sun-Load Sensor, Intake Air Temperature Sensor (Thermo AMP)

26 ) A/C (AUTO): Blower motor (mode, air source), Inside air/humid sensor, Outside air temperature sensor

AIR CONDITIONER 1. SYSTEM LAYOUT AND COMPONENTS Air Conditioner Controller FATC. Manual air conditioner

AIR CONDITIONER 1. SYSTEM LAYOUT AND COMPONENTS Air Conditioner Controller FATC. Manual air conditioner 06-2 6810-01 1. SYSTEM LAYOUT AND COMPONENTS Type Air Conditioner Controller FATC Manual air conditioner Sun Sensor - Instrument Panel Upper Left It changes sun load coming through front windshield into