14-Heating, Ventilation, Air Coniditioning

Heating,Ventilation, Air Conditioning

General Information
Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >
Electrical schematics
2000 > 2.5L GASOLIN(K5) >
Safety Precaution
1. R-134a liquid refrigerant is highly volatile. A drop of it on the skin could result in localized frostbite. When
handling the refrigerant, be sure to wear gloves.
2. If the refrigerant splashes into the eyes, wash them with clean water immediately. Always wear goggles or
glasses to protect the eyes.
3. The R-134a container is a highly pressurized vessel. Never subject it to intense heat, and be sure that the
temperature where it is stored is below 52°C (125.6°F)
4. A halide leak detector is often used to check the system for refrigerant leakage. R-134a, upon coming into
contact with the flame, produces phosgene, a toxic gas. Always provide adequate ventilation.
Safety Precaution
1. R-134a liquid refrigerant is highly volatile. A drop of it on the skin could result in localized frostbite. When
handling the refrigerant, be sure to wear gloves.
2. If the refrigerant splashes into the eyes, wash them with clean water immediately. Always wear goggles or
glasses to protect the eyes.
3. The R-134a container is a highly pressurized vessel. Never subject it to intense heat, and be sure that the
temperature where it is stored is below 52°C (125.6°F)
4. A halide leak detector is often used to check the system for refrigerant leakage. R-134a, upon coming into
contact with the flame, produces phosgene, a toxic gas. Always provide adequate ventilation.
2000 > 2.5L GASOLIN(K5) >
Air conditioning (A/C) system

The A/C system uses the principals of thermodynamics to cool passenger compartment of vehicle. Using engine power,
the compressor compresses gaseous refrigerant into high temperature/high pressure gas. If then pumps this gas into a
condenser unti built onto the vehicle’s radiator. The condenser cools gas, changing it into high pressure and low
temperature liquid refrigerant. The liquid then goes to receiver/drier, which first removes any liquid water and then sends
liquid to an evaporator in blower/evaporator unit inside passenger compartment. The evaporator then uses passenger
compartment temperature to turn the liquid back into a gas, extracting heat from passenger compartment. The gas is
then sent back to the compressor, and the cycle begins again.
A/C relay
A/C relay is an electrical switching box that closes the circuit connected with condenser fan relay and compressor clutch.
The relay is controlled by the engine control module (ECM) only. If the engine coolant exceeds a certain temperature, the
engine control module (ECM) sends a signal to trigger A/C relay and to shut off A/C system. AT starting or light
acceleration, the engine control module (ECM) sends a signal to trigger A/C relay and to shut off A/C system for five
seconds. It is a replaceable item.
Blower
The blower draws in passenger compartment air and sends it through the evaporator coil. It consists of a blower fan and
an electric motor.
Blower motor
Blower motor speed is controlled by the blower switch and the resistor assembly in the blower unit. When the blower
switch is in the OFF position, the motor ground circuit is open and the blower motor does not operate. When the switch is
in the first(LO) position, current flow from the blower motor is restricted by the three resistors in the resistor assembly,
and blower switch to second(M1), third(M2), or fourth(HI) positions causes the circuit resistance to decrease and the
blower motor speed becomes correspondingly faster.
Compressor assembly
The compressor assembly is the primary moving part of the air conditioning system. If it fails, there is no compression of
refrigerant, and no movement of refrigerant through system. It is located on the left side of the engine and is connected to
the engine crankshaft by a drive belt. It consists of the compressor, the manifold assembly, the compressor clutch, and
the drive pulley.
Compressor clutch
The compressor clutch engages the compressor. It is a magnetic unit operated from air conditioning switch in passenger
compartment. It is a serviceable and replaceable item.
Condenser
The compressor is mounted in front of radiator. It consists of a series of coils which cool refrigerant. It is a serviceable
and replaceable item.
Condenser fan
The condenser fan improves air flow through the condenser. The condenser will still have volume of air flowing through it
even if vehicle is standing still. It is powered by an electric motor connected to condenser fan relay. Condenser fan relay
is an electrical switching box that closes the circuit connected with condenser fan.
Evaporator assembly
The blower/evaporator assembly houses the blower fan, the blower motor, and the A/C relay for air conditioner system. It
consists of the evaporator core and the expansion valve.
Evaporator core
The evaporator core is and air cooler and a dehumidifier. As refrigerant enters it boils and absorbing heat from air being
blown through the core by heater blower motor. This cools the air, which is then directed to passengers through air ducts.
As the air is cooled, moisture in air condenses on the core and is drained off. The result is cold and dry air. The vaporator
core is a serviceable and replaceable item.
Expansion valve
The expansion valve allows high pressure liquid to expand as it enters evaporator. By allowing liquid to expand, it will
absorb more heat in evaporator. Valve also meters amount of refrigerant entering system to prevent evaporator core from
flooding.
Fresh/Recirculation actuator
When fresh/recirculate switch in heater and A/C control panel is pushed, motor in fresh/ recirculateion actuator assembly
moves and its position is not fed back to fresh/recirculation switch. When desired air fresh/recirculation door position is
reached, motor stops.
Heater
The dehumidified air is reheated as it passes through the heater core in heater unit. The heater is warmed by the engine
coolant passing through the tubes of the heater core. Heat is transferred to the core fins and passed off to the air flowing
past fins. The position of the air temperature valve in air conditioning module determines how much of total airflow is
permitted to pass through the heater. This determiner the warmth of overall air flow that is sent into the passenger
compartment.
Hoses and lines

Hoses and lines carry the refrigerant between the major components of A/C system. Lines are made of metal and are
rigid. Hoses are made of flexible rubber and are designed for either high or low pressure. They are replaceable items.
Receiver/Drier
The receiver/drier receives liquid refrigerant from the condenser, removes any water init, and then sends refrigerant to the
evaporator. It is a replaceable item.
Service ports
Service ports allow the injection or recovery of refrigerant to the A/C system. High-pressure service port is mounted in the
high pressure line coming from receiver/drier. Low-pressure service port is in the section of flexible hose that connects
the evaporator return line to the compressor.
Refrigerant (Refrigerant 134a (R-134a) systems)

In an effort or avoid the use ozone-depleting CFC refrigerants, Kia Motor Company has introduced a new refrigerant
system for this vehicle. This system uses non-CFC-based refrigerant R-134a.
This new type of refrigerant has many of the same properties as R-12 and is similar to R-12 in form and function. R-134a
is a hydrofluorocarbon (HFC)-based refrigerant, however, R-12 is a chlorofluorocarbon(CFC). With no chlorine atoms in
its molecular structure, use of R-134a refrigerandt will not have any harmful effects on the atmosphere’s ozone layer.
Identifying R-134a and R-12 A/C system

To determine which types of A/C system a particular vehicle has, inspect A/C system’s major components and refrigerant
lines for special tags. If system has yellow R-134a refrigerant. If there are no special R-134a “NON-CFC” tags on A/C
system components or lines, the system uses R-12.
Do not add R-12 Refrigerant to an A/C system that requires use if R-134a refrigerant. Do not add R-134a refrigerant
to an A/C system that requires use of R-12 refrigerant. These two types of refrigerant should never be missed.
Doing so may cause damage to A/C system.
Precaution for new refrigerant (R-134a)
R-12 and R-134a components are not interchangeable. Do not replace components from an R-134a system with
components for an R-12 system. Mixing components from these two types of system may cause component failure
and damage to A/C system.
R-134a system components

The major components of R-134a A/C system are similar to those used previously on R-12 systems. R-12 andR-134a
components are similar in design and function. As a result, all Removal and Installation procedures outlined for R-12
components can be for R-134a components.
• (Refer to operating instructions of your refrigerant recovery/recycling/charging station for proper procedures.)
2000 > 2.5L GASOLIN(K5) >
Troubleshooting table
Fault symptom
Blower motor operates with the blower switch OFF
Blower motor does not operate with the blower switch
Blower motor does not operate with the blower switch 1st position
Blower motor does not operate with the blower switch 2nd position
Blower motor does not operate with the blower switch 3rd position
Blower motor does not operate with the blower switch 4th position
No changing flow direction through out grille in the panel
Cool and warm air does not mix
Recirculation/fresh actuator does not operate
Compressor does not operate (Condenser fan operates normally)
Condenser fan does not operate (Compressor clutch operates normally)
Compressor and condenser fan do not operate
Insufficient cooling
Check refrigerant pressure Intermittent cooling
No cooling
Troubleshooting guide
Symptom : Blower motor operates with the blower switch OFF
Step Inspection Action

Disconnect the blower switch connector Yes Go to next step.
1 Go1. Turn the ignition switch ON, and
then check if blower motor operates. No Check blower switch.
Check wire harness between blower motor

and resister, and wire harness between blower
motor and blower switch.
Yes
Turn the ignition switch OFF and

disconnect resister connector G19. Turn
2
the ignition switch ON and check if Check wire harness between resister and
blower motor operates. blower switch.
No
Symptom : Blower motor does not operate with the blower switch ON
Check if FORT WIPER (15A) & FRONT Yes Go to next step.

1
HEATER(30A) fuses are good. No Replace fuse.
Turn ignition switch & blower switch ON. Yes Go to nest step.
2 Check if the voltage of blower motor connector Check wire harness between fuse and blower
G18-A(B.R) is 12V. No
motor connector G18-A(B/R).
Check if the voltage of blower motor connector Yes Go to nest step.

3
G18-B(L) is 12V. No Check the blower motor.
Yes Go to next step.
Check if the voltage of resister connector Check wire harness between blower motor
4
G19-D(L) is 12V. No connector G18-B(L) and resister connector
G19-B(L)
Check the ground condition and wire harness
Check if the voltage of blower switch
Yes between blower switch G01-34(B) and ground.
connector is 12V.
If normal, check the blower switch.
Check the wire harness between resister G19
and blower switch G01. If normal, check
5 resister.
No
Symptom : Blower motor does not operate with the blower switch 1st position.

Turn the ignition switch ON and set the
blower switch on 1st position, and then
1
check if the voltage if resister G19-D(Y) is
No Check resister and replace it if necessary.
12V.
Yes Check the blower switch.
Check if the voltage of blower switch Check wire harness between blower switch
2
connector G01-3B(Y) IS 12V. No connector G01-3B(Y) and resister
connector G19-D(Y).
Symptom : Blower motor does not operate with the blower switch 2nd position.

Turn the ignition switch ON, set the blower Yes Go to next step.
1 switch on 2nd position, and then check if
the voltage of resister G19-C(R) is 12V. No Check resister and replace it if necessary.
2 Check if the voltage of blower switch Yes Check the blower switch.
Check wire harness between blower switch
connector G01-D3(R) is 12V. No connector G01-3D(R) and resister
connector G19-C(R).
Symptom : Blower motor does not operates with the blower switch 3rd position.

Turn the ignition switch ON and set the
blower switch on 3rd position, and then
1
check if the voltage of resister G19-A(G) is
No Check resister and replace it if necessary.
12V.
Yes Check the blower switch.
Check if the voltage of blower switch Check wire harness between blower switch
2
connector G01-3E(G) is 12V. No connector G01-3E(G) and resister
connector G19-A(G).
Symptom : Blower motor does not operates with the blower switch 4th position.
Turn the ignition switch ON and set the Yes Check the blower switch.
blower switch on the 4th position, and then Check wire harness between blower switch
1
check if the voltage of blower switch No connector G01-3E(G) and resister
connector G01-3F(L) is 12V. connector G19-A(G).
Symptom : No changing flow direction through out grille in the panel

Turn the ignition switch OFF and disconnect
1 -
mode switch connector G20.
Check if the voltage if mode actuator
2 Check wire harness between fuse and
connector G20-B(R/G) is 12V. No
mode actuator.
Check for continuity between mode actuator Yes Go to next step.

3
connector G20-D(B) and ground G200. No Repair or replace BLK wire harness.
Check if mode actuator operates normally. Yes Go to next step.
4 Refer to “Mode actuator/Inspection;
page62-38” in this section. No Replace mode actuator.
5 Check the wire harness between mode switch Yes Check mode switch.
G01 and mode actuator G20.
No Repair or replace wire harness.
Symptom : Cool and warm air does not mix

1 -
MIX actuator connector G21.
Check if the MIX actuator operates when
Yes Go to step 4.
applying 12V to terminal G21-H(G/B) and
2
ground terminal G21-D(L/B), and then check it
No Go to next step.
again on the contrary.
Check MIX actuator. Refer to “MIX Yes Go to next step.
3 Actuator/Inspection: page 62-38” in this
section. No Replace MIX actuator.
Check the wire harness between MIX switch

Yes Check MIX switch.
G01 and MIX actuator G21.
4
Symptom : fresh/Recirculation actuator does not operate

1 -
Recirculation/fresh connector G01.
Set 12V to terminal G24-B(R/G) and Ground
Yes Go to step 4.
terminal G24-H(Y;REC) or G24-D(BR;FRE).
2
Check if FRE/REC actuator operates to each
No Go to next step.
direction.
Check FRE/REC actuator. Refer to “FRE/REC Yes Go to next step.
3 Actuator/Inspection: page 62-36” in this
section. No Replace FRE/REC actuator.
Check the wire harness between FRE/REC

4 Yes Check FRE/REC switch.
switch G01 and FRE/REC actuator G24.
Symptom : Compressor does not operate(condenser fan operates normally)
For Gasoline(KV6)

Turn the ignition switch, and A/C switch and blower
1 -
switch ON.
Check if the voltage of compressor connector B33 Check the wire harness
2
is 12V. No between A/C relay and
compressor B33.
3 Check if compressor is grounded normally.
No Repair ground.
4 Check the compressor clutch of compressor.
For Diesel (J3 TCI)
Check if A/C relay No.2 is good with Yes Go to next step.

1
disconnecting A/C relay No.2. No Replace A/C relay No.2.
Turn ignition, A/C and blower switch ON.
2 Check for continuity between G02-D(L/W) Check the wire harness between
and GND. No G02-D(L/W) and G01-2T(L/W). If good,
check A/C control unit.
Connect A/C relay No.2.Check if the Yes Go to next step.

3 voltage of Dual Pressure switch G04-A(R) Check the wire harness between G02-B(R)
is 12V. No
and G04-A(R).
Check if the voltage of Dual pressure Yes Go to next step.

4
switch G04-B(L) is 12V. No Check Dual pressure switch.
Yes Check A/C Compressor Clutch.
Check if the voltage of A/C Compressor
5 Check the wire harness between G04-B(L)
G05-A(L) is 12V. No
and G05-A(L).
Symptom : Condenser fan does not operate (Compressor clutch operates normally)
For Gasoline (KV6)

1 Turn the ignition switch, A/C switch and Yes Go to next step.
blower switch ON, and then check if the
voltage if the voltage of condenser fan Check the wire harness between A/C relay
No
B35-A(L) is 12V. and condenser fan B35-A(L).
Yes Check Condenser fan.

Check for continuity between condenser
2 Check the wire harness between
fan B35-B(B) and GND. No
condenser fan B35-B(B) and GND.
For Diesel(J3 TCL)
Check if A/C relay No.1 is good with Yes Go to next step.

1
disconnecting A/C relay No.1. No Replace A/C relay No.1.
Turn ignition, A/C and blower switch ON.
2 Check for continuity between G03-D(P) Check the wire harness between G03-D(P)
and GND. No and G01-2X(P). If good, check A/C control
unit.
Connect A/C relay No.1 and check if the Yes Go to next step.
3 voltage of A/C condensor fan motor Check the wire harness between G03-B(L)
G06-A(L) is 12V. No
and G06-A(L).
Yes Check the A/C condensor fan motor.
Check for continuty between G06-B(B) and
4 Check the wire harness between G06-B(B)
GND. No
and GND.
Symptom : Compressor and condenser fan do not operate
For Gasoline(KV6)

Turn the ignition switch, A/C switch and
clower switch ON, and then check if the
1
valtage of dual pressure switch B27-A(B/Y)
No Go to step 4.
is 12V.
Check if the voltage of dual pressure Yes Go to next step.

2
switch B27-B(L) is 12V. No Check dual pressure switch.
Yes Go to step 5.
Check if the voltage of engine control unit Check the wire hqrness between engine
3
B01-D25(L) is 12V. No control unit B01-D25(L) and dual pressure
switch B27-B(L).
Check the wire harness between air
Check if the voltqge of air conditioner Yes conditioner control unit G01-2T(B/Y) and
4 dual pressure switch B27-A(B/Y).
control unit G01-2T(B/Y) is 12V.
No Check air conditioner control unit.
Yes Go to next ste 5.
Check if the voltage of engine control unit Check the wire harness between engine
5
B01-C51(P) is 12V. No control unit B01-C51(P) and air conditioner
control unit G01-2X(P).
Yes Check engine control unit.
Check if the voltage of engine control unit
6 Check the wire harness between engine
B01-D29(G/B) is 12V. No
control unit B01-D29(G/B) and A/C relay.
For Diesel (J3 TCL)
Check if A/C(20) and R/WIPER(10A) fuses Yes Go to next step.

1
are good. No Replace fuses.
Check if A/C control unit and GND are Yes Recheck system.
2
good. No Repair or replace A/C control unit.
Symptom : checking refrigerant pressure.

1. Connect A/C manifold gauge set.
2. Operate engine at 1500 rpm.
3. Set blower switch on HI, turn A/C switch
ON.
4. Set MIX door on Max cooling position, Check the cooling performance. Refer to
1 then set FRE/REC door on "REC" position. Yes "Description and Operation/ Cooling
5. Measure the manifold gauge reading of Performance:page 62-22" in this section.
low and high-pressure sides.
Normal pressure
High pressure : 13.0~18.0 kg/cm²
Low pressure : 1.5~3.5 kg/cm²
High-pressure side : 8.0~10.0 kg/cm², Low-pressure side : 0.8~1.0 kg/cm²

Check for oil stains on the pipes, hoses No stains Go to next step.
1
and other parts. Stains Inspect the connection and replace O-ring.
No
Recharge refrigerant.
Check for leakage from all parts leakage
2
connections with gas leak tester. Inspect the leakge parts and replace parts
Leakage
and O-ring.
High-pressure side : 23 kg/cm², Low-pressure side : 2.5~3 kg/cm²

Check the condenser for bent fins or Yes Repair or replace.

1
dmage. No Dischare the excessive refrigerant.

High-pressure side : 21~25 kg/cm², Low-pressure side : 2.5~3 kg/cm²
Check the cooling performance. Refer to
Discharge, evacuate and charge the
1 "Description and Operation/Cooling
wywtem with refrigerant.
Performance : PAGE 62-22" in this section.
High-pressure side : 5.0~6.0 kg/cm², Low-pressure side : Vacuum

Discharge,replace receiver/drier,evacuate
Discharge, evacuate and charge the Yes
and charge.
1 system with refrigerant. Check if low and
high-pressure is normal. Inspect expansion valve and replace it if
No
necessary.
High-pressure side : 22.0~23.0 kg/cm², Low-pressure side : 2.5kg/cm²

Check if attachment condition of expansion
1 Inspect expansion valve and attach it again
valve is normal. No
if necessary.
Check if there is frost or heavy dew in the Yes Replace expansion valve.
2
suction pipe. No Recheck refrigerant pressure.
High-pressure side : 7.0~11.0 kg/cm², Low-pressure side : 4.0~6.0 kg/cm²

Inspect compressor and replace it if
Run engine at fast idle, set blower swit1ch Yes
necessary.
1 ON, and then turn A/C switch ON. Check if
compressor operates. Unspect magnetic clutch and replace ir if
No
necessary.
2000 > 2.5L GASOLIN(K5) >
Refrigerant System Service Basics (Refrigerant container service valve)

1. Turn the handle fully counterclockwise before connecting the valve to the refrigerant container.
2. Turn the outlet valve counterclockwise until it reaches its highest position.
3. Turn the outlet valve fully clockwise by hand.

Connect the center hose to the valve fitting.
4. Turn the handle clockwise to puncture the sealed can.
5. Turn the handle fully counterclockwise to fill the center hose.
Do not open the high or low-pressure manual valves.
6. Loosen the hose nut connected to the center fitting of the manifold gauge. Allow air to escape. Then retighten the nut.
Installation of manifold gauge set
Fittings for attaching the manifold gauge set are in the high and low-pressure pipes.
1. Close both hand valves of the manifold gauge set.

2. Connect the low-pressure hose and the high-pressure hose to fittings each.
3. Tighten the hose nuts by hand only.
Leak test
After evacuating the system, check for leaks.
1. Connect a full refrigerant container to the service valve.
2. Open the high-pressure manual valve to charge the system with refrigerant gas.
3. When the low-pressure gauge reads 14 psi (98kPa, 1kg/cm2), close the high-pressure manual valve.
4. Use gas leak detector to check the system for leaks. If a leak is found, repair t he fault component or connection and then
evacuate the system again.
Discharging
1. Connect the manifold gauge set to the refrigeration system.
2. Place the free end of the center hose on a shop towel.
3. Slowly open the high-pressure manual valve to allow the refrigerant to escape.
Open the valve only slightly.

If refrigerant is allowed to escape too fast, the compressor oil will be drawn out of the system.
4. Check the shop towel to make sure no oil is being discharged. If oil is present, partially close the manual valve.
5. After the manifold gauge reading drops below 50 psi (343kPa, 3.5kg/cm2), slowly open the low-pressure manual valve.
6. As the system pressure drops, gradually open both the high and low-pressure manual valves until both gauges read 0 psi
(0 kPa, 0kg/cm2).
Evacuation
Whenever the refrigeration system has been exposed to the atmosphere, it must be purged of moisture and air.
1. Connect the manifold gauge set.
2. Connect the center hose of the gauge set to the vacuum pump inlet.
3. Start the vacuum pump and open both manual valves.
4. When the low-pressure gauge indicates approximately 29.5 in Hg (750mmHg), close both manual valves and stop the
vacuum pump.
5. Verify that the pressure remains the same for 5 minutes of more. If the pressure changes, check the system for are leaks,
and repair as necessary.
6. If no leaks are found, disconnect the hose from the vacuum pump.
Charging
1. Evacuate the refrigeration system.
2. Connect the refrigerant container to the center hose of the manifold gauge set.
3. Open the high-pressure side manual valve to change system with refrigerant gas.
Refrigerant amount through high-pressure side : 100g (3.5 oz)

4. Close the high-pressure side manual valve of the manifold gauge set.
5. Start the engine and operate the compressor.
1) Be sure to keep the container in the upright position to prevent liquid refrigerant from being charged into the
system through the suction side, possibly damaging the compressor.
2) Never open the high-pressure side manual valve while charging the system with the A/C ON. Doing so may cause
the refrigerant can to explode.
3) While charging, it is not abnormal that a chattering sound will be heard.
6. Open the low-pressure side manual valve of the manifold gauge.

7. Charge the system with the specified amount of refrigerant.
8. Close the low-pressure side manual valve and the service valve of the refrigerant container.
9. Stop the engine.
10. Remove the manifold gauge set.
Performance test
After finishing repairs, conduct a performance test of the air conditioning sysytem as follows;
1. Connect the manifold gauge set.
2. Star the engine and keep the engine speed at 1,500rpm.
3. Operate the air conditioner at maximum cooling.
4. Open all windows and doors.
5. Place a dry-bulb thermometer in the center ventilator outlet.
6. Place a dry and wet thermometer close to the blower inlet.
7. Wait until the air conditioner outlet temperature stabilizes.
Stabilized condition Blower inlet

Air temperature : 25~35°C (77~95°F)
High-pressure side : 184~241 psi (1,275~1,667 kPa, 13.0~ 17.0 kg/cm²)
If the high-pressure side becomes too high, pour cool water on the condenser. If it is too low, cover the front of the
condenser.
8. After the air conditioner stabilizes, read the dry and wet thermometer at the air inlet.
9. Calculate the relative humidity from the chart below by comparing the wet and dry-bulb readings.
10. Read the dry thermometer at the air outlet, and calculate the difference between the inlet dry-bulb and outlet dry-bulb
temperatures.
11. Verify that the intersection of the relative humidity and temperature difference is in the shaded zone.
2000 > 2.5L GASOLIN(K5) >
Specifications
Description Specifications
Maximum cooling Front evaporator (Kcal/h) 4500±10%

capacity Rear evaporator (Kcal/h) 4100±10%
Front evaporator (CMH) 520
Cooling Air volume
Rear evaporator (CMH) 420
Front motor (W-V) 250-12
Power consumption
Rear motor (W-V) 200-12
Maximum heating Front heater (Kcal/h) 4500±10%

capacity Rear heater (Kcal/h) 4200±10%
Heating
Front heater (CMH) 330
Air volume
Rear heater (CMH) 310
Type Swash Plate 10PA 17C
Displacement (cc/Rev) 177.7
Compressor Number of cylinder 10
Oil (Capacity) ND-OIL 8 (200cc)
Power consumption (W-V) 45-12
Type Electronic
Magnetic clutch
Power consumption (W-V) 45-12
Type PF
Condenser Capacity (Kcal/h) 15000
Air volume (CMH) 1200
A/C
Type Laminated
components Front evaporator
Expansion valve Block type
ON (°C) 3.5
Duct sensor
OFF (°C) 1.5
Type Lamiated
Rear evaporator
Expansion valve Block type
Receiver/Driver Desiccant used Zeolite
OFF (Kg/cm²) 32
HIGH
Dual pressure DIFF (Kg/cm²) 6
switch OFF (Kg/cm²) 2.0
LOW
DIFF (Kg/cm²) 0.25
Heater Heater core Aluminum pin & Tube

components Actuator (Mode, MIX) Electronic
FRE/REC actuator Electronic
Refrigerant HIGH (Kg/cm²) 13.0~18.0
pressure
(1500RPM) LOW (Kg/cm²) 1.5~3.5
Refrigerant (Charged amount) (g) R-134a (1000±50g)


Air conditioning System

2000 > 2.5L GASOLIN(K5) >
Blower/Evaporator-front
Blower/Evaporator-rear
2000 > 2.5L GASOLIN(K5) >
Removal
1. Discharge refrigerant from A/C system. Refer to operating instructions of your refrigerant recovery/recycling
/charging station for proper procedures.
2. Disconnect inlet and outlet pipe from evaporator.
Immediately plug all open fittings to keep moisture out of system.
3. Remove cover and drain hose.

4. Remove instrument panel and disconnect wiring harness connector.
5. Remove blower/evaporator unit.
Installation
1. Install blower/evaporator unit in reverse order of removal.
2. Evacuate refrigerant system. Refer to operating instructions of your refrigerant recovery/recycling/charging
station for proper procedures.
3. Charge A/C system. Refer to operating instructions of our refrigerant recovery/recycling/charging station for
proper procedures.
1) Immediately plug all open fittings to keep moisture out of system.

2) Apply clean compressor oil to O-rings before connecting fittings.
3) Do not apply compressor oil to fittings.
4) When installing new evaporator, add compressor oil.
Compressor oil: 2.44 cu in (40 cc)

Tightening torque : 35~61 lb-in (4~7 N·m, 40~70 Kg-cm)

Air conditioning System - Compressor

2000 > 2.5L GASOLIN(K5) >
Component (Compressor-KV6 Engine (Gasoline))
Component (Compressor -J3 TCI Engine(Diesel))

2000 > 2.5L GASOLIN(K5) >
Removal (Gasoline)
1. Discharge refrigerant from A/C system. Refer to operating instruction of your refrigerant recovery/recycling
2. Disconnect high and low pressure hoses from compressor.
Immediately plug all open fittings to keep moisture out-of system.
3. Loosen the auto tension device and remove drive belt.

4. Remove mounting bolts from compressor.
5. Remove compressor.
Removal(Diesel)
2. Loosen the tension pulley bolt (A).
3. Remove adjusting bolt (B).
4. Remove belt.
5. Disconnect compressor clutch connector.
6. Disconnect high and low pressure hoses from compressor.
7. Remove mounting bolts from compressor.

8. Remove compressor.
Installation (Gasoline)
1. Install compressor in reverse order of removal.
2. Evacuate refrigerant system. Refer to operating instructions refrigerant recover/recycling/charging station for
proper procedures.
3. Charge A/C system. Refer to operating instructions of your refrigerant recovery/recycling/charging station
for proper procedures.


1) Adjust belt tension to specification.
Installation(Diesel)
1. Install compressor in reverse order if removal.

2) Apply clean compressor oil to O-ring before connecting fittings.
3) Do nor apply compressor oil to fittings.
Compressor oil: 2.44 cu in (40cc)
1) Adjust belt tension to specification.
Inspection (Gasoline)
1. Verify that blower motor runs when connecting 12V to compressor clutch terminal and ground compressor
body.
2. Check for oil stains on compressor clutch.

3. Check for damage or deform of clutch pulley.
4. Adjust clearance between pressure plate and rotor pulley by selecting and installing proper shim.
Clearance: 0.014~0.025 in (0.35~0.65 mm)
Inspection(Diesel)
1. Verify that blower motor runs when connecting 12V to compressor cluch terminal and ground compressor
body.
2. Check for oil stains on compressor clutch.

3. Check for damage or deform of clutch pulley.
4. Adjust clearance between pressure plate and rotor pulley by selecting and installing proper shim.
Clearance: 0.014~0.025 in (0.35~0.65 mm)


Air conditioning System - Condenser

2000 > 2.5L GASOLIN(K5) >
Removal
2. Remove front bumper, hood, horn and receiver/driver.
3. Remove condenser fan.
4. Remove liquid pipes.
5. Remove condenser.
1) Insert protector such as cardboard between condenser and radiator.

Installation
1. Install condenser in reverse order of removal.

4) When installing new condenser, add compressor oil.

Tightening torque: 35~61 lb-in (4~7 N·m, 40~70 Kg-cm)
Inspection
Check for following and repair or replace condenser as necessary.
1. Check damages or refrigerant leakage.
2. Bent fins.
3. Distorted or damaged condenser inlet or outlet.

Air conditioning System - Condenser fan & relay

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Verify that condenser fan runs when connecting 12V to condenser fan terminal G06-A(L)[Diesel, B35-A(L) :
Gasoline] and grounding terminal G06-B(B)[Diesel, B35-B(B) : gasoline].
2. If nor as specified, replace the condenser fan.
Removal
1. Remove front bumper.
2. Disconnect condenser fan connector.
3. Remove bolts and remove condenser fan.
Installation
1. Install condenser fan in reverse order of removal.
Tightening torque: 35~61 lb-in (4~7 N·m, 40~70 Kg-cm)


Air conditioning System - Receiver/Drier

2000 > 2.5L GASOLIN(K5) >
Removal
1. Discharge refrigerant from A/C system. Refer to operation instructions of your refrigerant recovery/recycling
2. Disconnect dual pressure switch connector.
3. Disconnect high and low pressure pipes.
4. Remove mounting bolts from receiver/driver.

5. Remove receiver/driver.
Installation
1. Install receiver/drier in the reverse order of removal.

2) Apply clean compressor oil to O-ring before connecting fittings.
4) When installing new receiver/drier, add compressor oil.
Compressor oil : 0,61 cu in(10 cc)


Air conditioning System - A/C control relay

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Disconnect A/C relay connector.
2. Check continuity between terminals.
Terminals
Continuity
Tester probe: + Tester probe: -
A D Yes
A C No
A B No
C D No
C B No
3. If not as specified, replace relay.

4. If correct, go to next step.
5. Apply 12V to terminal A and ground terminal D.

6. Check for continuity between terminals C and B.
Terminals Continuity
C-B Yes
7. If not as specified, replace relay.


Air conditioning System - Triple pressure switch

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Turn ignition switch OFF.
2. Connect manifold gauge set and measure high-pressure side refrigerant pressure.
High-pressure side : 184~213 psi (1275~1765 kpa, 13.0~18.0 kg/cm²)

Low-pressure side : 21.3~49.8 psi (147~343 kpa, 1.50~3.50 kg/cm²)
3. If not as specified, check refrigerant system referring to troubleshooting table on troubleshooting table.
4. If correct, go to next step.
5. Disconnect A/C dual pressure switch connector.

6. Check for continuity of switch.
Terminals Continuity
A-B Yes
7. If not as specified, replace switch.


Air conditioning System - Evaporator temperature
sensor

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Check for resistance between terminals.
Temperature (°C) Resistance (kΩ)

-20 22.5~25.9
-10 12.8~14.5
0 7.6~8.4
10 4.6~5.2
20 2.8~3.3
30 1.8~2.2
40 1.2~1.5
2. If nor as specified, replace the duct sensor.


Air conditioning System - Evaporator unit

2000 > 2.5L GASOLIN(K5) >
Replacement
Before replacement of expansion valve, carefully check refrigeration system.
1. Remove blower/evaporator assembly.

2. Disassemble blower/evaporator assembly and expansion valve as an assembly.
3. Replace expansion valve.
4. Install expansion valve in the reverse order of removal.
Apply clean compressor oil to O-rings before connecting fittings.


Heater

2000 > 2.5L GASOLIN(K5) >
Component
2000 > 2.5L GASOLIN(K5) >
Removal
1. Drain engine coolant. Refer to Engine Cooling System, Section 12.
2. Disconnect heater hoses from heater unit.
3. Remove instrument panel, refer to Body, Section 62
4. Remove heater unit.
Installation
1. Install heater unit in the reverse order of removal.

Heater - Temperature Control Actuator

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Verify that mix actuator operates when connecting 12V to mix actuator. Terminal G21-H(G/B) and grounding
terminal G21-D(L/B).
2. If not as specified, replace the mix actuator.


Heater - Mode Control Actuator

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Apply 12v to mode actuator terminal B and ground mode actuator terminal D.
2. Verify that mode actuator operates when grounding mode actuator terminals F, H, A, C, and G in sequence.
3. If not as specified, replace the mode actuator.


Blower - Blower Motor

2000 > 2.5L GASOLIN(K5) >
Blower motor-front
1. Disconnect blower motor connector.
2. Verify that blower motor runs when connecting 12V to terminal G18-A(B/R) and ground terminal G18-B(L).
3. If not as specified, replace the blower motor.
Blower motor-rear
1. Disconnect blower motor connector.
2. Verify that blower motor runs when connecting 12V to terminal G20-A(L/B) and ground terminal G20-B(B/R).
3. If not as specified, replace the blower motor.

Blower - Blower Resistor

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Disconnect resister connectors.
2. Check of continuity and resistance between terminals.
3. If not as specified, replace the resister assembly.


Blower - Intake Actuator

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Verify that Fresh/Recirculation actuator operates to fresh direction when Applying 12V to Fresh
/Recirculation actuator terminal G24-B(R/G) and grounding Fresh/Recirculation actuator terminal
G24-D(BR).
2. Verify that Fresh/Recirculation actuator operates to recirculation when grounding Fresh/Recirculation
actuator terminal G24-H(Y).
3. If not as specified, replace the Fresh/Recirculation actuator.


Blower - Blower Speed Controller

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Check continuity between terminal of blower switches.
2. If not as specified, replace the blower switches.

14-Heating, Ventilation, Air Coniditioning

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Heating,Ventilation, Air Conditioning

Heating,Ventilation, Air Conditioning

Model : Carnival / Sedona

Air conditioning (A/C) system

Hoses and lines

Refrigerant (Refrigerant 134a (R-134a) systems)

Identifying R-134a and R-12 A/C system

Precaution for new refrigerant (R-134a)

R-134a system components

Step Inspection Action

Check wire harness between blower motor

Turn the ignition switch OFF and

Check if FORT WIPER (15A) & FRONT Yes Go to next step.

Check if the voltage of blower motor connector Yes Go to nest step.

Step Inspection Action

Step Inspection Action

Step Inspection Action

Step Inspection Action

Symptom : No changing flow direction through out grille in the panel

Step Inspection Action

Check for continuity between mode actuator Yes Go to next step.

No Repair or replace wire harness.

Symptom : Cool and warm air does not mix

Step Inspection Action

Check the wire harness between MIX switch

Symptom : fresh/Recirculation actuator does not operate

Step Inspection Action

Check the wire harness between FRE/REC

Symptom : Compressor does not operate(condenser fan operates normally)

Step Inspection Action

For Diesel (J3 TCI)

Step Inspection Action

Check if A/C relay No.2 is good with Yes Go to next step.

Connect A/C relay No.2.Check if the Yes Go to next step.

Check if the voltage of Dual pressure Yes Go to next step.

For Gasoline (KV6)

Step Inspection Action

Yes Check Condenser fan.

For Diesel(J3 TCL)

Step Inspection Action

Check if A/C relay No.1 is good with Yes Go to next step.

Symptom : Compressor and condenser fan do not operate

Step Inspection Action

Check if the voltage of dual pressure Yes Go to next step.

For Diesel (J3 TCL)

Step Inspection Action

Check if A/C(20) and R/WIPER(10A) fuses Yes Go to next step.

Symptom : checking refrigerant pressure.

Step Inspection Action

High-pressure side : 8.0~10.0 kg/cm², Low-pressure side : 0.8~1.0 kg/cm²

High-pressure side : 23 kg/cm², Low-pressure side : 2.5~3 kg/cm²

Check the condenser for bent fins or Yes Repair or replace.

Step Inspection Action

High-pressure side : 5.0~6.0 kg/cm², Low-pressure side : Vacuum

High-pressure side : 22.0~23.0 kg/cm², Low-pressure side : 2.5kg/cm²

High-pressure side : 7.0~11.0 kg/cm², Low-pressure side : 4.0~6.0 kg/cm²

Refrigerant System Service Basics (Refrigerant container service valve)

3. Turn the outlet valve fully clockwise by hand.

Installation of manifold gauge set

1. Close both hand valves of the manifold gauge set.

Open the valve only slightly.

Refrigerant amount through high-pressure side : 100g (3.5 oz)

6. Open the low-pressure side manual valve of the manifold gauge.

7. Wait until the air conditioner outlet temperature stabilizes.