SM 10 PDF

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Heating,Ventilation, Air Conditioning
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
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• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name Illustration Description

Insulation gloves Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Used when inspecting or working on the high voltage

Insulation clothes
components
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Insulation helmet
Safety glasses
Used in the following cases :

• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
All removed high voltage components are placed on an

Insulation mat
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to

Insulation sheet protect people not wearing personal protective equipment from
safety accidents.
Warning tape Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.

• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
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Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 7feet(2m) or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage

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• Turn OFF the Button Start. Then keep the Smart Key 7feet(2m) or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
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Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 7feet(2m) or farther away from the vehicle to prevent unintended engine start.
(This is to prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. Remove the safety plug (A).
Remove the safety plug in the follwing order.

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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
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(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Specification
Air Conditioner
Item Specification
Type ESC33n (Electric Scroll)
Communication type CAN communication
Oil type & Capacity POE OIL, 180±10g
Compressor Motor type BLDC
Rated voltage 360V
Operation voltage 240~413V
Displacement 33cc/rev
Condensor Heat rejection 13,400 -3% kcal/hr
Air pressure transducer Pressure value Voltage=0.00878835*Pressure(psig)+0.5
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Expansion valve Type Block type

Type R-134a
Refrigerant Without heat pump 550±25g (19.4±0.88 oz.)
Capacity
With heat pump 900±25g (31.7±0.88 oz.)
Heater And Evaporator Unit

Item Specification
Type Fin & Tube type
PTC Heater Operating voltage DC 240V ~ 420V
Heating capacity 4,700 ± 5% kcal/hr
Exterior Condensor 17,000 - 3% kcal/hr
Heating capacity
Interior Condensor 2,600 - 5% kcal/hr
Heat Pump Chiller 770g
Accumulator 950cc
Mode operating type Actuator
Temperature operating type Actuator
Temperature contorl type Evaporator temperature sensor
Evaporator
A/C ON/OFF ON : 2.3±0.5°C, OFF : 0.6±0.5°C
Heating capacity 4,700 - 5% kcal/hr
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Special Service Tools

Personal Protective Equipment
Name Illustration Description

Insulation gloves components
[Insulation performance : 1000V / 300A or above]
Insulation shoes

Insulation clothes
components
Insulation helmet
Safety glasses Used in the following cases :

• When removing, installing or inspecting the high voltage
battery terminals or wiring where spark may occur.
• When working on the high voltage battery pack assembly.
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Face shield
Removed high voltage components are placed on the

Insulation mat
insulation mat to prevent safety accidents.
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High voltage components are covered with insulation sheet to
Insulation sheet protect people not wearing personal protective equipment from
safety accidents.
Troubleshooting
Problem Symptoms Table
Before replacing or repairing air conditioning components, first determine if the malfunction is due to lack of refrigerant, air flow or
compressor.
Use the following table to find the cause of the problem. The numbers indicate the order of the likely cause of the problem. Check each part
in order. If necessary, replace the corresponding parts.
After fixing the area of malfunction, check the complete system to ensure satisfactory performance.
Standard :
Symptom Suspected Area
1. Blower fuse
2. Blower motor
No blower operation 3. PWM blower module
4. Blower speed control switch
5. Wire harness
1. Engine coolant capacity
No air temperature control
2. Heater control assembly
1. Refrigerant capacity
2. A/C fuse
3. Limiter clutch
4. Compressor
No compressor operation
5. A/C pressure transducer
6. A/C switch
7. Evaporator temperature sensor
8. Wire harness
Vented air not cold 1. Refrigerant capacity
2. Refrigerant pressure
3. Drive belt
4. Limiter clutch
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5. Compressor
8. A/C switch
10. Wire harness
1. Refrigerant capacity
2. Drive belt
3. Limiter clutch
4. Compressor
5. Condenser
Insufficient cooling
6. Expansion valve
7. Evaporator
8. Refrigerant lines
1. MCU
No engine idle-up when A/C switch ON
2. Wire harness
No air inlet control 1. Heater control assembly
No mode control 1. Heater control assembly
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1. Cooling fan fuse
2. Fan motor
No cooling fan operation
3. Engine ECM
4. Wire harness
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 off immediately with clean water.
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 lubricant for R-134a systems. If lubricants other than the recommended type are used, system failure may occur.
6. POE 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 the components immediately to prevent 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. Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
8. Since the electric compressor uses high-voltage, you should use POE oil which have high volumetric resistivity.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
9. If an accidental discharging occurs in the system, ventilate the work area before resuming the service.
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When replacing parts ON A/C system

1. Never open or loosen a connection before the system has been discharged.
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.
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When Installing Connecting Parts
Flange With Guide Pin
Check new O-ring for any damage (use only the specified) and lubricate with compressor oil. Tighten the nut to specified torque.
• T stands for tensile intensity and is stamped on the head of each bolt in numerals.
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 the refrigeration system needs to be opened, have everything you will need to service the system ready so the system will not be
left open any longer than it is necessary.
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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.
Refrigeration Cycle
Refrigerant System Service Basics

• Since the electric compressor uses high-voltage, POE oil with high volumetric resistivity should be used.
• Do not use the same A/C recovery / charging station as in conventional belt-driven compressors.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the A/C
compressor may not work.
Refrigerant Recovery
Use only U.L.-listed service equipment that is certified to meet the requirements of SAE J2210 when removing HFC-134a (R-134a) from the
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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 to 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) and the low-pressure service port (C) as shown, following
the equipment manufacturer's instructions.
[Without Heat Pump]
[With Heat Pump]

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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
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.)
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 pressure does not reach over 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there may be a leakage in the system. Partially
charge the system and check for any leakages (see Leak Test).
4. Remove the low pressure valve from the low-pressure service port.
System Charging
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Recovery/Recycling/Charging System (A) to the high-pressure service port (B) as shown, following the equipment manufacturer's
instructions.
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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 R-134a refrigerant. Do not overcharge the system as it may damage the compressor.
Specified amount
Without heat pump : 550 ± 25g (19.4 ± 0.88 oz.)
With heat pump : 900 ± 25g (31.7 ± 0.88 oz.)
Refrigerant Leak Test

Always conduct a leak test with an electronic leak detector whenever leakage of refrigerant is suspected and when conducting service
operations that accompany disassembling, loosening or connecting of 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 tightening torque of the connection fittings, and if it is too loose, tighten to the proper torque. Using a leak detector (A), check
for gas leakage.
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. Replace at all times even for a slight damage.
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.
Component Location Index

Engine Room
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[Without Heat Pump]
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1. Receiver-drier 6. Suction & Liquid tube
2. Condensor 7. Expansion valve
3. A/C Pressure Transducer (APT) 8. Suction pipe
4. Service port (Low pressure) 9. Suction hose
5. Service port (High pressure) 10. Electric A/C compressor
[With Heat Pump]

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1. Electric A/C compressor 6. 3 ways solenoid valve assembly
2. Receiver-drier 7. Accumulator
3. Exterior condensor 8. 2 ways solenoid valve assembly
4. Refrigerant temperature sensor #1 9. Refrigerant temperature sensor #2
5. Chiller 10. Expansion valve
Interior
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1. Photo sensor
2. Heater & Blower unit
4. Heater & A/C control unit
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Oil Specification
1. The HFC-134a system requires synthetic compressor oil (POE) whereas the R-12 system requires mineral compressor oil. The two oils
must never be mixed.
2. Compressor oil (POE) varies according to compressor model. Be sure to use oil specified for the model of compressor.
A. Since the electric compressor uses high-voltage, POE oil with high volumetric resistivity should be used.
B. Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
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• If the POE oil of the system gets mixed with PAG oil, then dielectric breakdown due to decreased volumetric resistivity can occur
and inoperative A/C compressor may result, A/C compressor may not work.
• If the POE oil gets mixed with PAG oil, replace the compressor with new one and clean inside the A/C system (condenser,
refrigerant line, evaporator and etc.)
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 and R-1234yf
compressor oils are prone to absorb moisture.)
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.
Total volume of oil in system
POE OIL : 180 ±10cc (6.1 ± 0.3 oz.)
Oil Recovery Operation
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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 components of the system, the compressor must be running in advance of oil recovery operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine, turn the air conditioning switch "ON" and set the blower motor control knob to 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.
Component Location
[Without Heat Pump]
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1. Refrigerant line
[With Heat Pump]

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1. Refrigerant line
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 tightened to over the specified torque.
Items N.m kgf.m lb-ft

Compressor 20.0 ~ 33.0 2.0 ~ 3.4 14.8 ~ 24.3
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Accumulator mounting bolt

Discharge hose mounting bolt
Discharge pipe mounting bolt
6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0
Suction pipe mounting bolt
Suction hose mounting bolt
Tube & Hose assembly mounting bolt
Accumulator nut
Discharge hose nut
Discharge pipe nut
7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Suction pipe nut
Suction hose nut
Tube & Hose assembly nut
Refrigerant valve 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Chiller (Refrigerant line) 5.9 ~ 9.8 0.6 ~ 1.0 4.3 ~ 7.2
4. Evacuate air in the refrigeration system and charge system with refrigerant.
Specified amount
Without heat pump : 550 ± 25g (19.4 ± 0.88 oz.)
With heat pump : 900 ± 25g (31.7 ± 0.88 oz.)
5. Inspect for leakage of refrigerant.
Using a gas leak detector, check for leakage of refrigerant.
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6. Inspect A/C operation.
Specification
Model ESC33n
Motor BLDC Motor
Control Type CAN
Compression Type Scroll
Capacity 33cc/rev
Operating Voltage Range 190~320V
Rated Voltage 288V
Mount Type Bracket Mounting, 4 Point Mounting
Components Location
[Without Heat Pump]
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1. Electric A/C compressor
[With Heat Pump]

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1. Electric A/C compressor
Components
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1. Control Part 3. Compression Part
2. Motor Part
Description
Electric compressors improve the fuel efficiency and operates the air conditioner even when the engine has stopped.
Operation Principle
Compression Part
One of the scrolls is fixed while the other orbits eccentrically without self-rotating, thereby to trap and pump refrigerant in the pockets
between the scrolls.
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Motor Part
Converts electric power into a mechanical motion with Brushless DC Motor.
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Control Part
Converts direct current to 3-phase alternating current and alters the compressor speed to cope with cooling demand.
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. If the compressor is marginally operable, run the engine, and let the air conditioning work for a few minutes, then shut the engine off.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit.
(Refer to EV Battery system - "High Voltage Shut-off Procedure")
4. Recover the refrigerant with a recovery/charging station.
•
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If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
5. Disconnect the compressor connector (A) and high voltage connector (B) after loosening bolt.
• Disconnect high voltage connector by pressing the locker pin (A) and pressing the lever (B).
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6. Remove the fixing clip of compressor high voltage cable (A).
7. Remove the engine room under cover.

(Refer to Traction Motor System - "Under Cover")
8. Remove the engine room under side cover [LH].
(Refer to Traction Motor System - "Under Cover")
9. Remove the suction hose (A) and discharge hose (B) after loosening bolts and nuts.
[Without Heat Pump]

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[With Heat Pump]
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• When separating the refrigerant line, it must cover the plug or cap for protecting the A/C system from the humidity and dust.
10. Remove the electirc A/C compressor (A) after loosening the mounting bolts.
[Without Heat Pump]
[With Heat Pump]

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Installation
1. Make sure that the compressor mounting bolt with the correct length is screwed in. Tighten the mounting bolts to the specified tightening
order.
Tightening torque :
10.0 ~ 15.0 N.m (2.04 ~ 3.36 kgf.m, 7.37 ~ 11.0 lb-ft)
2. Install in the reverse order of removal and note the followings:

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 125±10cc. The result is the amount of oil you should drain from the new compressor (through the suction
fitting).
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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.
Troubleshooting
Fault code Fail description Remedy

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60 Compressor CAN signal fault 1. Check HV, LV connector connection.

2. Check LV connector pin condition.
3. Check vehicle inverter fuse condition.
61 Compressor operation state error receive
4. A/C ON then check compressor operation.
5. If not operating, replace compressor.
1. Check HV connector connection.
2. Check vehicle inverter fuse condition.
62 Low voltage 3. Check voltage level of high voltage battery.
1. Identify vehicle model on compressor
2. Check voltage level of high voltage battery.
63 High voltage
1. Check heating object in engine room.
2. Check A/C system for defects.
64 Overheat protection 3. After 20 minutes, IG ON and A/C ON then check compressor
operation.
65 Overloaded 1. Check cooling fan operation.
66 Over current protection 2. Check AAF(Active Air Flap) for short circuit
3. After 20 minutes, IG ON and A/C ON then check compressor
68 Missed restart
operation.
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71 Failure of Over torque stall 4. If not operating, replace compressor.
1. Check 12V battery fuse.
2. Check LV connector connection.
67 Abnormal (not receiving)
3. Check FATC CAN connection.
69 Failure of thermistor open
1. Check thermistor condition and inspect.
70 Failure of thermistor short
72 Failure of short circuit current
73 Failure of driver voltage
1. Replace compressor.
74 Failure of current measuring
2. Check vehicle inverter fuse (if necessary, replace).
75 Failure max temperature gradient
76 Failure Internal Error
Component Location
[Without Heat Pump]
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1. Condenser
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
1. Recover the refrigerant with a recovery/ recycling/ charging station.
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• Since the electric compressor uses high-voltage, you should use POE oil which have high volumetric resistivity.
3. Shut off the high voltage circuit. (Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
5. Remove the side air guard (A) by pulling it upward after pressing the locking hook in the direction of the arrow.
[LH]
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[RH]
6. Remove the refrigerant line (A) after loosening the mounting nuts.
7. Separate the condenser (C) from the radiator after loosening the mounting bolt.
[LH]
[RH]
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8. Remove the condenser assembly (A) from the radiator assembly.
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9. Install in the reverse order of removal and note the followings :
A. If you're installing a new condenser, add refrigerant oil (POE OIL).
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.
Replacement
[Without Heat Pump]
1. Remove the condenser, and then use an L wrench to remove the bottom cap (B) from the condenser.
Tightening torque :
9.8 ~ 14.9 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)
2. Remove the desiccant (A) from the condenser using a long nose plier. Check for crumbled desiccant and clogged bottom cap filter.
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3. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
4. Insert a 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 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.
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• Charge the system, and test its performance.
[With Heat Pump]
• Since the electric compressor uses high-voltage, you should use POE oil which have high volumetric resistivity.
(Refer to Body - "Front Bumper Cover")
5. Remove the receiver-drier (A) after loosening the mounting bolts.
6. Install in the reverse order of removal.

7. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
8. Insert a new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed to air for use.
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9. 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 sure to use the
Component Location
[Without Heat Pump]
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[With Heat Pump]

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Description
The A/C Pressure Transducer (APT) converts the pressure value of high pressure line into voltage value after measuring it. Engine ECU
converts the voltage value to control the cooling fan by operating it in high speed or low speed. Engine ECU stops the operation of the
compressor when the temperature of refrigerant line is very high or very low irregularly to optimize air conditioning system.
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Inspection
1. Measure the pressure of high pressure line by measuring voltage output between terminals No. 1 and No. 2.
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2. Inspect the voltage value whether it is within the specified range.
Voltage= 0.00878835 * Pressure + 0.5[PSIA]

3. If the measured voltage value is not within the specification, replace the A/C pressure transducer.
Replacement
2. Recover the refrigerant with a recovery/charging station.
3. Disconnect the A/C pressure transducer connector (A).
4. Remove the A/C pressure transducer (B).
[Without Heat Pump]

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[With Heat Pump]
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• Be careful not to bend the liquid & suction pipe.
• When installing, replace it with a new O-ring (A).
Description
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay power in order to prevent
evaporator from freezing by excessive cooling
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Inspection
1. Turn the ignition switch OFF.
2. Disconnect the evaporator temperature sensor connector.
3. Measure the resistance between terminals "1" and "2" of the evaporator temperature sensor.
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4. Connect the evaporator temperature sensor connector.
5. Run the engine and turn the A/C switch ON, then measure the voltage between the terminals of the harness connector.
Specification
Evaporator core
Resistance[KΩ]
temperature[°C(°F)]
-10 / (14) 43.35
0 / (32) 27.62
10 / (50) 18.07
20 / (68) 12.11
30 / (86) 8.3
40 / (104) 5.81
Replacement
2. Remove the console side cover (A).
[RH]
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3. Disconnect the evaporator temperature sensor connector (A).
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4. Remove the evaporator temperature sensor (A) by pulling it out after rotating it 90° in a counterclockwise direction.

Description
The In-car air temperature sensor is integrated into the heater & A/C control unit.
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 in-
car temperature to intended value.
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Description
The photo sensor is located at the center of the defrost nozzles.
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.
Inspection
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1. Turn the ignition switch ON.
2. Connect the GDS.
3. Emit intensive light toward the 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.
1. Auto Light Signal 5. Led GND (To BCM)

2. Auto Light Signal Signal 6. Photo Signal (LH)
3. Photo Signal (RH) 7. Photo Power (SW)
4. Led power (BAT) 8. 5V (Vcc)
Replacement
2. With the (-) driver, remove the photo sensor (A) from the center of the defrost nozzle.

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Description
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 temperature.
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.
Inspection
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2. Disconnect ambient temperature sensor.
3. Check the resistance of the ambient temperature sensor between terminals 1 and 2 whether it is changed by changing of the ambient
temperature.
1. Sensor Ground 2. Ambient Sensor Signal
Specification
Ambient temperature
Resistance between terminals 1and 2 (kΩ)
[°C(°F)]
-10(14) 158.18
0 (32) 95.10
10 (50) 58.80
20 (68) 37.32
4. If the measured resistance is not within the 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
2. Remove the engine room under cover.
(Refer to Traction Motor Systerm - "Under Cover")
3. Disconnect the connector and then remove the ambient temperature sensor (A).
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Description
The cluster ionizer makes disinfection and decomposition of bad smell from the air-conditioner or inflow air. And it cleans the inside air of a
vehicle.
When the air-conditioner or heater is operating, it starts from "CLEAN" mode and alternates from "CLEAN" mode to "ION" mode and vice
versa for every 15 minutes.
In the "CLEAN" mode, the cluster ionizer generates negative ions and positive ions and disinfects and decomposes bad smells from the air-
conditioner or inflow air.
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It has an operation indicator lamp on the display area that shows its operating status.
In the “ION” mode, the cluster ionizer generates negative ions and cleans the inside air of a vehicle. It has an operation indicator lamp on the
display area that shows its operating status.
Inspection
1. Press the MODE switch more than 4 times within 2 seconds while pressing the OFF switch.
Display Fail description
00 Normal
50 Cluster ion generator fault
* For diagnostic procedures, refer to DTC code.
Replacement
2. Remove the glove box and glove box housing.
(Refer to Body - “Glove Box Housing”)
3. Disconnect the cluster ionizer connector (A).
4. Loosen the screws and then remove the cluster ionizer (A).
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Component Location
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1. Heater unit
Components
[LH]
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1. Floor shower duct assembly [LH] 12. Ventilation guide
2. Duct sensor 13. Heater case [LH]
3. Interior condenser cover 14. Duct sensor
4. Heater core cover 15. Joint flange cap
5. Temp door arm 16. Interior condenser
6. Temp door lever 17. Evaporator core lower insulation
7. Temp actuator motor assembly 18. Floor door assembly
8. Floor door lever 19. Vent door assembly [LH]
9. Mode actuator motor assembly [LH] 20. Cowl top cover - Heat seal
10. Mode cam 21. Cowl top cover - Heat seal
11. Motor & wheel assembly 22. Cowl top cover - Heat seal
[RH]
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1. Evaporator core 10. Defogging actuator motor assembly
2. Joint flange cap 11. Vent door arm
3. Heater lower door 12. Mode cam
4. Temperature control door 13. Mode actuator motor assembly [RH]
5. Floor door assembly [RH] 14. PWM blower motor
6. Vent door assembly [RH] 15. Floor door lever
7. Defogging door assembly [LH] 16. Floor door arm
8. Ventilation guide 17. Floor shower duct assembly [RH]
9. Heater case [RH] 18. Drain hose
Replacement
• Put on gloves to protect your hands.

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• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
(Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the cowl top cover.
(Refer to Body - "Cowl Top Cover")
5. Remove the pipe (A) after loosening the mounting bolts.
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6. Remove the expansion valve (A) after loosening the mounting bolts from the evaporator core.
Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)
• Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
7. Loosen the cowl cross member mounting bolts (A).
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8. Remove both sides of front seat assembly.

(Refer to Body - "Front Seat Assembly")
9. Remove the floor console assembly.
(Refer to Body - "Floor Console Assembly")
10. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
11. Remove the glove box housing.
(Refer to Body - "Glove Box Housing")
12. Remove the crash pad center panel.
(Refer to Body - "Crash Pad Center Panel")
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13. Remove both sides of the front pillar trim.
(Refer to Body - "Front Pillar Trim")
14. Remove both sides of the cowl side trim.
(Refer to Body - "Cowl Side Trim")
15. Remove the steering column shroud lower panel.
(Refer to Body - "Steering Column Shroud Panel")
16. Remove the steering wheel.
(Refer to Steering System - "Steering Wheel")
17. Remove the multifunction switch.
(Refer to Body Electrical System - "Multifunction Switch")
18. Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
19. Remove the rear airduct assembly (A).
[LH]
(1) Remove the accelerator pedal fixing cap (A).
(2) Remove the accelerator pedal (A) after loosening the mounting bolt.
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(3) Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
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(4) Bend the front floor carpet backwards.
(5) Remove the rear air duct assembly (A) after loosening the mounting nut.
[RH]
(7) Bend the front floor carpet (A) backwards.

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20. Remove the shift lever assembly.
(Refer to Automatic Transaxle System - "Shift Lever")
21. Disconnect the airbag control module (SRSCM) connector (A).
22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
23. Disconnect the passenger compartment junction box connectors (A).

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24. Remove the passenger compartment junction box mounting clips (A).
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25. Disconnect the multi box connectors (A).
[Driver's]
[Passenger's]
26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]
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[Passenger's]
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27. Remove the drain hose (A).
28. Disconnect the high voltage PTC heater cable (A).
• How to press the high voltage PTC heater cable locker pin
1. Pull the locker pin (A) in the direction of the arrow.
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2. While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
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29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
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30. Disconnect the heater and blower unit connectors.
(1) Remove the high voltage heater ground (A) after loosening the mounting bolt (B) and fixing clip (c).
(2) Remove the fixing clip (B) after disconnecting the intake actuator connector (A).
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(3) Remove the fixing clip (B) after disconnecting the blower unit connector (A).
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(4) Remove the fixing clip (B) after disconnecting the PWM unit connector (A).
(5) Remove the fixing clip (B) after disconnecting the blower motor connectors (A).
(6) Disconnect the temperature control actuator connector (A) and duct sensor connector (B).
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(7) Remove the fixing clip (B) after disconnecting the mode control actuator conenctors (A).
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(8) Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).
31. Remove the mounting clips (A).

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32. Loosen the heater and blower unit mounting bolts (A).
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33. Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.
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34. Remove the air duct (A) after loosening the mounting screw.
35. Disconnect the connector (B).

And then remove the high voltage line guide (A) after loosening the mounting screws.
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36. Disconnect the high voltage PTC heater unit connector (A).
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37. Remove the high voltage PTC heater unit (A) after loosening the mounting screws.
38. Remove the high voltage PTC heater core (A) after loosening the mounting screws.
39. Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).
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40. Install in the reverse order of removal and note the followings:
A. If you're installing a new evaporator, add refrigerant oil. (POE OIL)
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.
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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 coolanSince the electric compressor uses high-voltage, POE oil with high resistivity should be
used.tIf PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and
the A/C compressor may not work.
Replacement
damage.
4. Remove the heater and blower unit assembly.
(Refer to Heater -"Heater Unit")
• After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether. (Refer to the below removal
procedure.)
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5. Remove the fixing clip (A) after loosening the mounting screws.
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6. Remove the heater lower case (B) after loosenig the heater lower case mounting bolt (A).
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7. Pull out the evaporator core (A) from the heater unit.
•
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If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
• If you're installing a new evaporator core, add refrigerant oil (PAG OIL).
• Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
• Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off
immediately.
• Apply sealant to the grommets.
• Make sure that there is no air leakage.
• Charge the system and test its performance.
• Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
• Refill the cooling system with engine coolant.
Operation Condition
1. The power supplied to the PTC heater should be within DC 240V - 420V (high voltage).
2. The power supplied to the PTC heater should be within 9.0V - 16.0V (low voltage).
3. The interlcok and insulation resistance must be normal.
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4. The engine must be running.
5. The high voltage PTC heater operates depending on the operating Duty output.
6. If the high voltage PTC heater is abnormal, check the Fail Safe.
Inspection
1. Check for output signal in the heater and A/C control unit.
2. Using the GDS, check whether there is a problem in the interlock.
3. Check whether the low voltage (12V) is supplied or not.
4. For inspection, refer to the Self Diagnosis and Fail Safe.
Replacement
damage.
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(Refer to EV Battery System - "High Voltage Shut-off Procedure")
(Refer to Body -"Floor Console Assembly")
(Refer to Body -"Crash Pad Lower Panel")
(Refer to Body -"Glove Box Housing")
(Refer to Body -"Crash Pad Center Panel")
7. Remove the TPMS receiver.
(Refer to Suspension System -"Tire Pressure Monitoring System")
8. Remove the high voltage PTC heater ground (A) after loosening the mounting bolt.
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1. Pull the locker pin (A) in the direction of the arrow.
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2. While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
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Description
The heater unit includes mode control actuator and temperature control actuator.
Located in the heater unit, the temperature control actuator regulates the temperature in the following procedures.
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Signal from control unit adjusts the position of the temperature door by operating the temperature switch. Then the temperature will be
regulated by the hot/cold air ratio decided by the position of the temperature door.
Inspection
2. Disconnect the temperature control actuator connector.
3. Verify that the temperature control actuator operates to the cool position when 12V is connected to terminal 3 and ground to terminal 7.
Verify that the temperature control actuator operates to the warm position when connected in reverse.
1. - 5. Feedback signal
2. - 6. Sensor ground
3. Cool position 7. Warm position
4. Sensor (+ 5V)
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4. Connect the temperature control actuator connector.
6. Check the voltage between terminals 5 and 4.
Specification
Door Position Voltage (V) Error Detecting
Max. cooling 0.3±0.15 Low voltage : 0.1V or less
Max. heating 4.7±0.15 High voltage : 4.9V or more
It will feedback the current position of the actuator to controls.

7. If the temperature control actuator does not operate well, substitute with a known-good temperaturecontrol actuator and check for proper
operation. Use the replaced actuator if it performs well.
Replacement
3. Remove the driver's side shower duct (A) after loosening the screw.
4. Disconnect the connector (A) and then remove the temperature control actuator (B) after loosening the mounting screws.
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Description
Located in the heater unit, the mode control actuator adjusts the position of the mode door by operating the mode control actuator according
to the signal from the A/C control unit. Pressing the mode select switch shifts the mode control actuator in the order of Vent → Bi-Level →
Floor → Mix.
Inspection
2. Disconnect the mode control actuator connector.
3. Verify that the mode control actuator operates to the defrost mode when 12V is connected to terminal 3 and ground to terminal 7.
Verify that the mode control actuator operates to the vent mode when connected in reverse.
2. - 6. Sensor (+ 5V)
3. Defrost mode 7. Vent mode
4. Sensor ground
4. Connect the mode control actuator connector.

Specification
Door position Voltage (V) Error detecting
Vent 0.3±0.15 Low voltage : 0.1V or less
Defrost 4.7±0.15 High voltage : 4.9V or more

7.
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If the mode control actuator does not operate well, substitute with a known-good mode control actuator and check for proper operation.
Use the replaced actuator if it performs well.
Replacement
[Driver's Mode Actuator]
3. Remove the driver shower duct (A) after loosening the mounting screw.
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5. Disconnect the mode control actuator connector (A).
And then remove the mode control actuator (B) after loosening the mounting screws.
[Passenger's Mode Actuator]

2. Remove the main crash pad assembly.
(Refer to Body - "Main Crash Pad Assembly")
3. Disconnect the mode control actuator connector (A).
And then remove the mode control actuator (B) after loosening the mounting screws.
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Inspection
3. Verify that the auto defogging actuator operates to the open position when 12V is connected to terminal 3 and ground to terminal 4.
Verify that the auto defogging actuator operates to the close position when connected in reverse.
4. Connect the auto defogging actuator connector.
3. DEF (OFF) 7. Sensor (+ 5V)
4. DEF (ON)
Specification
Defog OFF (CLOSE) 0.30±0.15 Low voltage : 0.1V or less
Defog ON (OPEN) 3.0±0.15 High voltage : 4.9V or more

7. If the auto defogging actuator does not operate well, substitute with a known-good auto defogging actuator and check for proper
operation. Use the replaced actuator if it performs well.
Replacement
3. Remove the driver shower duct (A) after loosening the mounting screw.
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Heat Pump Configuration and Operation
Heat pump is configured to circulate refrigerant flow for cooling/heating function.
This process minimizes battery consumption by the heater resulting in enhanced driving distance of EV.
[Heating]
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1. Outer Condenser - Evaporates liquid refrigerant and forms low temp-low pressure gas substance.
2. 3-Way Solenoid Valve #2 - Redirects the refrigerant direction towards the chiller when heat pump is active.
3. Chiller - Uses waste heat from the motor and performs secondary heat exchange on low temp-low pressure gas.
4. Accumulator - Separates gas/liquid so that only the refrigerant in gas state can flow into the compressor.
5. Electric Compressor - Compressor is operated by electric motor. Converts low temp-low pressure gas refrigerant into high temp-high
pressure gas and sends it to inner condenser.
6. Inner Condenser - Condenses high temp-high pressure gas refrigerant and transforms it into high temp-high pressure liquid refrigerant.
7. 2-Way Solenoid Valve #1 - Instantly expands refrigerant to create low temp-low pressure refrigerant.
8. 2-Way Solenoid Valve #2 - Sends the refrigerant to the evaporator if DEFROST Mode is used when heating.
9. 3-Way Solenoid Valve #1 - Bypasses the refrigerant to chiller if refrigerant accumulation in the outer condenser is detected.
[Cooling]
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1. Outer Condenser - Condenses high temp-high pressure gas refrigerant and transforms it into high temp-high pressure liquid refrigerant.
2. 3-Way Valve #2 - Directs refrigerant flow to expansion valve when A/C is operating.
3. Expansion Valve - Instantly expands refrigerant to create low temp-low pressure gas.
4. Evaporator - Operates blower fan to cool the air passing through the evaporator pin while the refrigerant in foggy state is transformed into
gas (surrounding area gets cold).
5. Accumulator - Separates gas/liquid so that only gas state refrigerant can flow into the compressor.
6. Electric Compressor - Compressor is operated by electric motor. Converts low temp-low pressure gas refrigerant into high temp-high
pressure gas and sends it to inner condenser.
7. Inner Condenser - Condenses high temp-high pressure gas refrigerant and transforms it into high temp-high pressure liquid refrigerant.
8. 2-Way Solenoid Valve #1 - Does not expand but circulates refrigerant when A/C is operating.
9. 2-Way Solenoid Valve #2 - Prevents refrigerant from flowing into evaporator.
10. 3-Way Solenoid Valve #1 - Circulates refrigerant to outer condenser.
Components Location
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1. 3-Way Solenoid Valve Assembly 2. 2-Way Solenoid Valve Assembly
Description
Changes the valve outlet direction with an electric signal to switch the refrigerant flow direction. This switching of refrigerant flow direction
allows activation of A/C Mode and Heat Pump Mode.
Inspection
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1. Vcc 2. Ground
Check the voltage between terminals 6 and 7.

1. Using the tester, check the resistance between terminals 1 and 2.
Temperature
Resistance [KΩ]
°C °F
-30 -22 8.7~9.5
-25 -13 8.92~9.74
-20 -4 9.14~9.98
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-15 5 9.37~10.23
-10 14 9.59~10.47
-5 23 9.81~10.71
0 32 10.03~10.95
5 41 10.25~11.19
10 50 10.47~11.43
15 59 10.69~11.67
20 68 10.90~11.90
25 77 11.12~12.14
30 86 11.34~12.38
35 95 11.55~12.61
40 104 11.77~12.85
Replacement
[3-WAY Solenoid Valve]
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.Since the electric compressor uses
high-voltage, POE oil with high resistivity should be used.
3. Disconnect the 3-WAY solenoid valve connector (A).
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4. Remove the refrigerant line after loosening the mounting nuts (A).
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5. Remove the 3-WAY solenoid valve assembly (A) after loosening the mounting bolt and nut.
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[2-WAY Solenoid Valve]

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3. Disconnect the 2-WAY solenoid valve connector (A).
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5. Remove the 3-WAY solenoid valve assembly (A) after loosening the mounting bolt and nut.
Components Location
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1. Accumulator
Description
Separates refrigerant in gas/liquid state so that only the refrigerant in gas state can flow into the compressor.

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Replacement
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4. Remove the accumulator (A) after loosening the mounting bolt.
Components Location
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1. Refrigerant Temperature Sensor #1 2. Refrigerant Temperature Sensor #2
Description
Monitors refrigerant temperature in A/C duct and sends resistance data to A/C controller. (same as the thermistor)
Temperature and resistance is inversely proportioned.
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Inspection
1. Vcc 2. Ground
Check the voltage between terminals 6 and 7.

1. Using the tester, check the resistance between terminals 1 and 2.
Temperature Resistance
°C °F Specification [KΩ] Tolerance [%]
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-40 -40 225.1 ± 3.06
-30 -22 129.3 ± 2.49
-20 -4 76.96 ± 1.95
-10 14 47.34 ± 1.46
0 32 30 ± 1.00
10 50 19.53 ± 1.43
20 68 13.03 ± 1.82
30 86 8.896 ± 2.19
40 104 6.201 ± 2.54
50 122 4.406 ± 2.86
60 140 3.186 ± 3.16
70 158 2.343 ± 3.44
80 176 1.749 ± 3.71
90 194 1.325 ± 3.96
100 212 1.017 ± 4.20
110 230 0.789 ± 4.42
120 248 0.62 ± 4.63
Replacement
[Refrigerant Temperature Sensor #1]
2. Seperate the charge door handle (A).
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3. Loosen the clips and bolts on the front bumper upper cover.
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4. Lift the front bumper uppser cover (A) slightly.
5. Remove the front bumper upper cover (A) after loosening the mounting screw (B) on the side.
6. Remove the refrigerant temperature sensor #1 (B) after disconnecting the refrigerant temperature sensor #1 connector (A).
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[Refrigerant Temperature Sensor #2]

2. Remove the refrigerant temperature sensor #2 (B) after disconnecting the refrigerant temperature sensor #2 connector (A).
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Components Location
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1. Inner Condenser
Description
Uses high temp-high pressure refrigerant to warm the air flowing into the interior (same role as the heater core in a conventional system).
Replacement

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damage.
(Refer to Body -"Cowl Top Cover")
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Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)

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[LH]
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[RH]
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22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
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[Driver's]
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[Passenger's]
[Driver's]
[Passenger's]
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(1) Pull the locker pin (a) in the direction of the arrow.
(2) While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
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30. Remove the interior condensor cover (A) after loosening the mounting screws.
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31. Remove the interior condenser (A) in the direction of the arrow.Since the electric compressor uses high-voltage, POE oil with high
resistivity should be used.
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• If you're installing a new condenser, add refrigerant oil (POE OIL).
Components Location
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1. Outer Condenser
Description
Condenses high temp-high pressure refrigerant when in A/C Mode (same role as the condenser in a conventional system).
Evaporates low temp-low pressure refrigerant when in Heating Mode (same role as the evaporator in a conventional system).
It is designed as down-flow type to facilitate condensed liquid discharge.
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Replacement
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damage.
(Refer to Body -"Front Bumper Cover")
5. Remove the ambient temperature sensor.
(Refer to Heating,Ventilation, Air Conditioning -"Ambient Temperature Sensor")
6. Remove the refrigerant temperature sensor #1.
(Refer to Heating,Ventilation, Air Conditioning -"Refrigerant Temperature Sensor #1")
7. Separate the refrigerant line (A) after loosening the mounting nuts.
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8. Pull out the side air guides (A) after pushing locker hook in the direction of the arrow.
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9. Separate the exterior condensor (B) from the radiator after loosening bolts (A).
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10. Remove the exterior condenser (A) in the direction of the arrow.Since the electric compressor uses high-voltage, POE oil with high
resistivity should be used.
• If you're installing a new condenser, add refrigerant oil (POE OIL).
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Components Location
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1. Chiller
Description
Recycles waste electric heat by using the waste heat from electrical motor to exchange heat in low temperature refrigerant.
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Replacement
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2. Drain the coolant.
(Refer to Traction Motor System - "Coolant")
4. Remove the reservoir tank.
(Refer to Traction Motor System - "Reservoir")
5. Separate the refrigerant line (A) after loosening the mounting bolt.
6. Separate the refrigerant line (A) after loosening nut and then remove the chiller coolant hose (B).
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7. Remove the chiller (A) after loosening the mounting bolts.
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3-Way Coolant Valve

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1. 3-Way Coolant Valve
Description
Switches the valve outlet direction through electric signal to change refrigerant flow direction.
Directs refrigerant flow towards chiller when heating pump is activated.
Directs refrigerant flow towards radiator during normal condition.
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1. Towards radiator
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2. Towards chiller
3. Inlet
Replacement
1. Drain the coolant.
(Refer to Traction Motor System - "Coolant")
3. Disconnect the 3-WAY solenoid coolant valve connector (A).
4. Remove the 3-WAY coolant valve connector fixing clip (B).
5. Remove the coolant hose (A) above 3-WAY coolant valve.
6. Remove the coolant hose (A).

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7. Remove the 3-WAY coolant valve (B) after loosening the mounting bolts.

Component Location
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1. Blower unit
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Components
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1. High voltage PTC heater core 10. Intake cam
2. Ionizer 11. Intake arm
3. Evaporator temperature sensor 12. Blower - crash pad seal
4. Air inlet filter cover assembly 13. Air filter
5. Heater core pipe mounting bracket 14. Inlet door assembly
6. Heater - evaporator seal 15. Case clip
7. Intake duct case [LH] 16. Air inlet door assembly
8. Intake arm 17. Intake duct case [LH]
9. Intake actuator motor assembly 18. Evaporator - heater seal
Replacement

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damage.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used..
(Refer to Body - "Cowl Top Cover")
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Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)
• Replace the O-rings with new ones.
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[LH]
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[RH]
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22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A)..

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[Driver's]
[Passenger's]
[Driver's]
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[Passenger's]
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(1) Pull the lock pin (A) in the direction of the arrow.
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(2) While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
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30. Disconnect the heater and blower unit connectors.
(1) Remove the high voltage heater ground (A) after loosening the mounting bolt (B) and fixing clip (c).
(2) Remove the fixing clip (B) after disconnecting the intake actuator connector (A).
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(3) Remove the fixing clip (B) after disconnecting the blower unit connector (A).
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(4) Remove the fixing clip (B) after disconnecting the PWM unit connector (A).
(5) Remove the fixing clip (B) after disconnecting the blower motor connectors (A).
(6) Disconnect the temperature control actuator connector (A) and duct sensor connector (B).
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(7) Remove the fixing clip (B) after disconnecting the mode control actuator connectors (A).
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(8) Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).
31. Remove the mounting clips (A).

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32. Loosen the heater and blower unit mounting bolts (A).
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33. Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.
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34. Remove the air duct (A) after loosening the mounting screw.
35. Disconnect the connector (B).

And then remove the high voltage line guide (A) after loosening the mounting screws.
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36. Disconnect the high voltage PTC heater unit connector (A).
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Inspection
1. Connect the battery voltage and check for the blower motor rotation.
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2. If the blower motor voltage does not operate well, substitute with a verified blower motor and check for proper operation.
3. If the problem is corrected, replace the blower motor.
Replacement
3. Remove the driver shower duect (A) after loosening the mounting screw.

5. Remove the fixing clip (B) after disconnecting the mode control actuator connector (A).
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6. Disconnect the temperature control connector (A).

And then remove the temperature control actuator (B) after loosening the mounting screws.
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7. Remove the brake pedal.
(Refer to Brake System - "Brake Pedal")
8. Disconnect the blower motor connector (A).
And then remove the blower motor (B) after loosening the mounting screws.
9. Install the reverse order of removal.

Inspection
2. Manually operate the control switch and measure the voltage of blower motor.
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3. Select the control switch to raise voltage until high speed.
Replacement
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3. Disconnect the connector (A) and then remove the blower resistor (B) after loosening the mounting screws.

Description
The climate control air filter is located in the blower unit. It eliminates foreign materials and odor. The particle filter performs a role as an odor
filter as well as a conventional dust filter to ensure comfortable interior environment.
Replacement
1. Open the glove box (A).
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2. Remove the air filter panel (A).
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3. Remove the filter cover (A) by pressing the filter cover knob.
4. Replace the air filter (A) with a new one according to the direction of air filter.
• To remove the filter easily, press the righthand side inward and then pull out the filter.
• In case of driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as possible.
Description
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The intake actuator is located in the blower unit. It regulates the intake door by signal from control unit. Pressing the intake selection switch
will shift between recirculation and fresh air modes.
Inspection
2. Disconnect the intake actuator connector.
3. Verify that the actuator operates to the recirculation position when 12V is connected to terminal 3 and ground to terminal 7.
Verify that the intake actuator operates to the recirculated air position when connected in reverse.
3. Fresh air 7. Recirculated air
4. Sensor (+ 5V)
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4. Connect the intake actuator connector.
Specification
Fresh air 0.3±0.15 Low voltage : 0.1V or less
Recirculated air 4.7±0.15 High voltage : 4.9V or more

7. If the intake actuator does not operate well, substitute with a verified intake actuator and check for proper operation. Use the replaced
actuator if it performs well.
Replacement
3. Disconnect the connector (A) and then remove the intake actuator (B) after loosening the mounting screws.
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Components
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Connector Pin Function
Pin
Connector A Connector B Connector C
No.
1 ILL (+) Ground Electric compressor interlock (+)
2 Sensor REF (+5V) Sensor ground Electric compressor interlock (-)
3 C_CAN High Blower PWM IN High voltage PTC heater interlock (+)
4 C_CAN LOW Ionizer diagnosis High voltage PTC heater interlock (-)
5 Driver mode actuator (VENT) - PAB IGN3
6 Driver mode actuator (DEF) CLEAN signal PAB ON signal
7 Driver mode actuator F/B Passenger mode actuator (VENT) PAB OFF signal
8 Intake actuator (FRE) Passenger mode actuator (DEF) SBR
9 Intake actuator (REC) Passenger mode actuator F/B Rr LEFT SBR
10 Intake actuator F/B Defogging actuator (OPEN) Rr CENTER SBR
11 K-LINE Defogging actuator (CLOSE) Rr RIGHT SBR
12 HTD Defogging actuator F/B -
13 Rear defog switch Vent left duct sensor (+) -
14 Temp. control actuator (COOL) Floor left duct sensor (+) -
15 Temp. control actuator (WARM) IGN3 -
16 Temp. Control actuator F/B IGN2 -
17 Left seat heater indicator - LOW -
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18 Left seat heater indicator - MID 2 WAY valve #1 (+)

19 Left seat heater indicator - HIGH 3 WAY valve #1 (+)
20 ILL - (RHEO) 3 WAY valve #2 (+)
21 DETENT OUT (+) 2 WAY valve #2 (+)
22 Left seat heater switch CLIMATE_CAN HIGH
23 Left ventilation indicator - LOW CLIMATE_CAN LOW
24 Left ventilation indicator - MID HUMIDITY (PWM)
25 Left ventilation indicator - HIGH Air pressure tranducer signal
26 Right seat heater switch Refrigerant temperature sensor signal #1
27 Ambient sensor (+) Refrigerant temperature sensor signal #2
28 Evaporator sensor (+) Coolant valve OUTPUT
29 Right ventilation indicator - LOW IGN3
30 Right ventilation indicator - MID Blower IS
31 Right ventilation indicator - HIGH Battery
32 Photo sensor (-) Battery
33 Right ventilation switch
34 Left ventilation switch
35 Blower INH
36 MM_CAN HIGH
37 MM_CAN LOW
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38 Right seat heater indicator - LOW
39 Right seat heater indicator - MID
40 Right seat heater indicator - HIGH
Self Diagnosis
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 temperature display panel
every 0.5 second and will show two figures. Codes are displayed in numerical format
3. Fault code display
(1) Continuous operation : DTC code for one.
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(2) Continuous operation : DTC code for two or more.
(3) STEP operation

A. Same as continuous operation when normal or one fault code.
B. DTC code for two or more.
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Replacement
damage.
2. Using a screwdriver or remover, remove the center fascia panel (A).
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3. Disconnect the A/C & heater controller connectors (A).
4. Remove the heater & A/C controller unit (A) from the center fascia panel (B) after loosening the mounting screws.
• Make sure that the connectors are connected in properly.

• Replace any damaged clips.

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Page 1 sur 127

Heating,Ventilation, Air Conditioning

• All the high voltage wiring and connectors are in orange.

Name Illustration Description

Used when inspecting or working on the high voltage

Used in the following cases :

All removed high voltage components are placed on an

Insulation sheet is used to cover high voltage components to

Personal Protective Equipment Inspection

• Check that the personal protective equipment is not damaged.

Precautions when handling high voltage battery

• Battery Control System - Refer to "High Voltage Battery Handling Guide"

Precautions in case of fire in High Voltage Battery System

Precautions in case of high voltage battery gas and/or electrolyte leakage

Precautions when handling vehicle after an accident

Precautions when EV is unattended for a prolonged period

Hybrid Vehicle Refrigerant Recovery / Charging Precautions

Heating,Ventilation, Air Conditioning

High Voltage Shut-off Procedure

Remove the safety plug in the follwing order.

(3) Remove the high voltage cable (A).

Expansion valve Type Block type

Heater And Evaporator Unit

Special Service Tools

Name Illustration Description

Used when inspecting or working on the high voltage

Used when inspecting or working on the high voltage

Safety glasses Used in the following cases :

Removed high voltage components are placed on the

Heating,Ventilation, Air Conditioning

Heating,Ventilation, Air Conditioning

When replacing parts ON A/C system

Handling tubing and fittings

The Following precautions must be observed

Heating,Ventilation, Air Conditioning

Refrigerant System Service Basics

[Without Heat Pump]

[With Heat Pump]

Refrigerant Leak Test

Heating,Ventilation, Air Conditioning

Component Location Index

[Without Heat Pump]

[With Heat Pump]

Compressor Oil Check

Oil Recovery Operation

[With Heat Pump]

Heating,Ventilation, Air Conditioning

• Connections should not be tightened to over the specified torque.

Items N.m kgf.m lb-ft

Accumulator mounting bolt

Heating,Ventilation, Air Conditioning

[With Heat Pump]

Heating,Ventilation, Air Conditioning

Heating,Ventilation, Air Conditioning

7. Remove the engine room under cover.

[Without Heat Pump]

[With Heat Pump]

[Without Heat Pump]

[With Heat Pump]

2. Install in the reverse order of removal and note the followings:

Fault code Fail description Remedy

60 Compressor CAN signal fault 1. Check HV, LV connector connection.

Heating,Ventilation, Air Conditioning