Air Conditioning

GENERAL INFORMATION REMOVAL AND INSTALLATION
1. SPECIFICATION.................................... 3 6810-20 FATC SELF DIAGNOSIS............. 45

2. MAJOR CHANGES................................. 4 6810-20 HEATER AND A/C CONTROL
SWITCH...................................... 49
6810-00 AIR CONDITIONER MODULE
OVERVIEW AND OPERATING SWITCH...................................... 55
PROCESS 6810-12 MODE ACTUATOR SWITCH....... 61
6810-11 TEMPERATURE ACTUATOR
1. SYSTEM LAYOUT................................. 6 SWITCH...................................... 64
2. HEATER AND A/C CONTROL................ 8 6810-02 INTAKE ACTUATOR SWITCH.... 67
3. A/C COOLING CYCLE............................ 12 6810-00 WATER TEMPERATURE
4. A/C COOLING CIRCUIT......................... 14 SENSOR..................................... 69
5. CIRCUIT DIAGRAM................................ 16 6810-24 INTAKE SENSOR....................... 71
6810-06 MOS MODULE........................... 73
6810-05 BLOWER MOTOR ASSEMBLY.. 75
CONFIGURATION AND FUNCTION 6810-03 AIR FILTER ASSEMBLY............ 77
6810-15 PTC HEATER............................ 79
6810-00 AIR CONDITIONER MODULE...... 18
6820-00 AIR CONDITIONER HOSE AND
PIPE............................................ 19
6830-00 AIR DISTRIBUTOR...................... 20
6810-20 HEATER AND A/C CONTROL
ASSEMBLY................................ 21
6810-00 AIR CONDITIONER MODULE..... 29
6810-15 PTC HEATER ASSEMBLY......... 43
6810-00 01-3
1. SPECIFICATION
Description Specification
Heater Core size (㎣) 200 x 165.5 x 25
Capacity (kcal/h) 4,800
Evaporator Core size (㎣) 254.8 x 196.75 x 60
Blower Supply power (W) 240 + 10% Max (at 12 V)
Fan speed (rpm) 2900±200 Max
(Rec.Mode: 420㎥/h)
PTC Supply power 1 kW
Condenser Core size (㎣) 588 x 455 x 16 (2,625)
Capacity of receiver drier 250 cc
compressor Capacity 170 cc/rev
Diameter of pulley Ø120
Max. continuous speed 8,000 rpm
voltage DC 12 V
Power consumption 2.2 A
01-4
2. MAJOR CHANGES
1) Heater & Evaporator Module (Wiring Specification)
Ambient temperature sensor signal Blower max signal wiring added

wiring added to vehicle wiring to vehicle wiring connecting
connecting connector (2 circuits) connector (1 circuit)
: manual A/C : manual A/C & FATC
Manual A/C: Wiring pin added to controller assembly connector

FATC: Wiring pin added to existing connector of controller assembly
The driving circuit for the manual A/C ambient temperature sensor is added, giving the change to
the heater and evaporator module.
6810-00 01-5
2) Manual A/C Controller

Manual air conditioner controller
Previous Current
Connector added
The driving circuit for the ambient temperature sensor is added to the manual air conditioner
controller for ambient temperature display on the instrument cluster.
Pin No. Function

B1 -
B2 -
B3 -
B4 Water temp. signal
B5 -
B6 -
B7 -
B8 -
B9 -
B10 Sun-load sensor signal
B11 Ambient temp. sensor signal
B12 -
01-6
1. SYSTEM LAYOUT
Line & port
Low pressure hose
High pressure hose
Electric fan
A/C condenser & receiver drier A/C compressor
Integrated
receiver
drier
6810-00 01-7
FATC Incar sensor
Sun-load sensor
Refrigerant pressure
sensor
Engine ECU
Ambient temperature
sensor
01-8
2. HEATER AND A/C CONTROL

1) Full Automatic A/C Control
Temperature dial Mode dial Fan speed dial
Recirculation switch A/C switch
▶ Temperature dial
Temperature dial
- To adjust the temperature, turn this
dial as required. Turning the dial to
HI increases the temperature and
LO decreases the temperature. Recirculation switch
- When you press this switch,

recirculation indicator comes on
and the system is changed into
the recirculation mode.
(However, under defroster mode
or defroster/floor mode, it stays
in the fresh air mode.)
6810-00 01-9
▶ Mode dial
- The air flow direction can be controlled by turning the dial.
Face/Foot-Level Foot-Level
(bi-level mode) (foot mode)
Foot/Defrost-level
(foot/defrost mode)
Face-Level
(vent mode)
Defroster switch
Airflow is changed Use this switch to remove for

automatically according to or ice from the windshield.
the setting temperature. When choosing this mode, the
airflow direction will be
Incar sensor changed to the windshield and
side glasses, the air
This sensor detects the inside temperature
conditioner operates
and installed in PCB.
automatically, and fresh air
comes in.
▶ Fan speed dial
Fan speed dial

- Manual control
Fan speed is manually controlled
by this dial. The increment is 1℃.
- Auto control
A/C switch
Fan speed is automatically
When pressing this
controlled by temperature setting.
switch, the air conditioner
The blower motor operates in a
operates in manual mode
stepless mode.
and A/C ON indicator
comes on.
01-10
2) Manual A/C Control
Fan speed dial Mode dial Temperature dial
A/C switch Recirculation switch
▶ Fan speed dial
Fan speed dial

The fan speed can be
adjusted by rotating the
switch. To stop the operation,
A/C switch turn the dial to the "OFF"
When pressing the switch position.
with the engine running, the The level is adjustable in 7
A/C compressor operates steps.
and the indicator comes on.
Pressing the switch again
deactivates the compressor
and turns off the indicator.
6810-00 01-11
▶ Mode dial
Face/Foot-Level Foot-Level (foot mode)

(bi-level mode)
Foot/Defrost-level
(Foot & defrost mode)
Face-Level (vent mode)
Defrost mode
Use this switch to remove fog or ice
from the windshield.
When pressing this switch, the airflow
direction will be changed to windshield
and door glasses, the A/C is operated
automatically and the air source mode
is set to fresh air mode.
▶ Temperature dial
Temperature dial
Rotate this dial to adjust the
temperature.
Recirculation switch
Turning this switch clockwise
When pressing this switch, the air (red side) increases the
is recirculated in the vehicle and temperature and
the indicator on the switch comes counterclockwise (blue side)
on. decreases the temperature.
When pressing it again, the
indicator goes off and the fresh
air comes in.
When it's rainy or humid, set this
switch to fresh air mode with the
defroster mode selected to clear
the fogged windshield.
01-12
3. A/C COOLING CYCLE
1) System flow
- "Compression -> Condensation -> Expansion -> Evaporation"
2) Functions
(1) Compressor
- Condition: Gas
- Function: Circulates the refrigerant and increases the pressure and temperature for easier
evaporation.
(2) Condenser
- Condition: Gas/Liquid
- Function: Cools and condenses the refrigerant by using ambient air to liquefy it under high
pressure.
(3) Receiver drier
- Condition: Gas/Liquid
- Function: Keeps the refrigerant free from moisture by separating/collecting the moisture from it.
(4) Expansion valve

- Condition: Liquid/Liquefied gas
- Function: Performs adiabatic expansion and flow control for easier evaporation.
(5) Evaporator
- Condition: Liquefied gas/Gas
- Function: Cools the air by absorbing the heat from the air around the evaporator.
6810-00 01-13
3) Description for Each Cycle

(1) Compression
- The evaporated refrigerant in the evaporator enters to the compressor. And the refrigerant gas
is compressed until it can be liquefied at ambient temperature.
- Thus, the low refrigerant pressure is maintained so that the liquid refrigerant can be
evaporated actively at low temperature (around 0℃).
(2) Condensation
- The high pressure and high temperature gas (refrigerant) from the compressor is cooled
down by the fresh air entered into the condenser. Then, this gas is converted to liquid and
collected in the receiver drier.
- The heat generated from the high pressure refrigerant is dissipated to the ambient air, and it is
called "heat of condensation".
The heat of condensation is the summation of the heat of vaporization (heat that the
refrigerant absorbs from the inside of the vehicle) and the calorific value converted from the
amount of work which is needed to compress.
(3) Expansion
- The liquid refrigerant lowers the pressure making its evaporation easily accomplished.
- This process (lowering the pressure to the level at which evaporation easily takes place
before the liquid refrigerant is sent to the evaporator) is called
"Adiabatic Expansion".
- During adiabatic expansion, the expansion valve lowers the pressure of the refrigerant and
determines the correct amount of refrigerant going into the air conditioning evaporator.
- That is, the amount of heat, which is needed to stop the evaporation, is determined
according to the cooling load.
- The expansion valve detects this and regulates the amount of the refrigerant exactly.
(4) Evaporator
- The refrigerant is converted from liquid to gas in the evaporator.
(The refrigerant in the form of fog in the evaporator is vaporized actively)
- At this time the refrigerant, in the form of liquid, absorbs the heat in the air which is need for
evaporation (latent heat) and is cooled down. Then the blower blows the cooled air inside the
vehicle to lower the temperature.
- There are liquid refrigerant from the expansion valve and evaporated refrigerant in the
evaporator.
- The evaporation temperature can be predicted from the evaporation pressure (i.e. relationship
between saturation pressure and saturation temperature).
- It is important to keep the pressure inside the evaporator low, so that the refrigerant is
evaporated at low temperature to make sure the completely evaporated refrigerant is entered
into the compressor.
01-14
4. A/C COOLING CIRCUIT

01-16
5. CIRCUIT DIAGRAM
6810-00 01-17
01-18
1. Blower assy 12.Mode actuator assembly

2. Intake actuator assy 13.Heater core assy
3. Air filter assembly 14.Evaporator core
4. Air filter cover 15.PTC heater assembly
5. Blower motor assy 20.Heater and A/C control assembly
6. MOS module 21.Screw
7. Expansion valve assy 22.Ventilation insert assy
9. Heater & evaporator wiring assy 23.In-car sensor motor
10.Heater & evaporator assy 24.Intake sensor
11.Temperature actuator assy
6820-00 01-19
1. Condenser assy 12.Liquid & suction pipe assy

2. A/C compressor assy 13.Nut
3. Discharge & suction hose assy 14.Suction O-ring
4. Nut 15.Liquid O-ring
5. Suction O-ring 16.Suction O-ring
6. Discharge O-ring 17.O-ring
7. O-ring 18.Drain hose
9. Heater inlet hose assy 22.A/C compressor bracket assy
10.Heater outlet hose assy 23.Bolt
11.Clamp 24.Bolt
01-20
1. Foot duct
2. Foot duct
3. Rear heating No. 1 duct assy
6. Nut
6810-20 01-21
Recirculation switch Dial indicator
Temperature dial Switch indicator
Mode dial In-car sensor
Fan speed dial (Blower dial)

Compressor switch
The FATC (Full Automatic Temperature Control) is a temperature control device which receives
signals from various sensors (in-car sensor, ambient temperature sensor, water temperature
sensor, sun-load sensor) and control switches to control the blower motor and all kinds of
actuator (mode door actuator, mix door actuator, intake door actuator) through MICOM in the
FATC. Therefore the interior temperature of the vehicle is kept to the temperature which is set by
a driver.
The driver can check the status of A/C through the dial indicator of FATC. The fan speed and the
temperature are adjusted automatically by the input values from different sensors to keep indoor
air fresh.
If the FATC system has any defect, the MICOM performs self-diagnosis for the system to make it
easier to detect the fault.
01-22
1) FATC Input/Output Diagram
▶ A/C compressor control by engine ECU

1. Coolant temperature: -20℃ or less
2. Coolant temperature: 115℃ or higher
3. For approx. 4 seconds immediately after starting the engine
4. Engine speed: 650 rpm or less
5. Engine speed: 4,500 rpm or higher
6. During abrupt acceleration for the vehicle equipped with manual transmission
6810-20 01-23
2) Major Features
(1) Temperature control
In full AUTO mode, the FATC receives various
signals such as the indoor temperature, ambient
temperature, engine coolant temperature, sunlight,
from different sensors to control the A/C
compressor, mode door, intake actuator assembly,
air mix door, blower motors, etc. to keep indoor
environments fresh.
(2) Blower control

In full AUTO mode, the blower motor is controlled automatically according to the set temperature.
The blower motor speed can also be controlled manually.
▶ Manual control
Fan speed is manually controlled by this dial.
The increment is 1℃.
Blower step Blower motor voltage (V)

1 4.0
2 5.0
3 6.5
4 8.5
5 10.5
6 VIGN
▶ Auto control
Fan speed is automatically controlled by temperature setting. The blower motor operates in a
stepless mode.
▶ Control in relation to sun-load

The system increases the fan speed by adding up 2.5 V of voltage in direct sunlight.
▶ Control for defrosting

When the defrost mode is selected with the blower dial in AUTO position, the blower motor
voltage is increased by 1.5 V compared to the AUTO control voltage for a certain amount of
time.
01-24
▶ Heating start control

When the engine coolant temperature is low or the wind temperature is not warmed up
sufficiently, the driver might feel uncomfortable by the air flow from the vent. Therefore,
the fan speed is set to the 1st stage and the cool air is sent to the windshield until the
coolant temperature increases to the proper level (DEF mode).
As the engine coolant temperature goes up, the mode is changed to Defrost & Foot
mode or AUTO mode to increase the speed of blower motor.
This control is cancelled when the output value of the water temperature sensor is
approximately 62℃.
▶ Cooling start control

When the intake temperature sensor indicates over 35°C, the driver might feel
uncomfortable by the air flow from the vent.
Therefore, at the initial operation stage, the hot air is discharged to the windshield (DEF
mode) for about 5 seconds.
▶ Control for defrosting
When the defrost mode is selected with the blower dial in AUTO position, the blower
motor voltage is increased by 1.5 V compared to the AUTO control voltage for a certain
amount of time.
3) Intake Fresh/Recirculation Control

▶ Manual control
The air source door can be controlled manually by pressing the air source mode switch.
The air source mode is switched between the fresh air and recirculation alternatively each
time the switch is pressed.
6810-20 01-25
▶ AUTO control
In auto mode, the basic setting for the air source is fresh air. When the ambient temperature
is high during cooling, the air source is changed from fresh air to recirculation to lower the
temperature.
▶ Control by vehicle speed (heating)

When the vehicle is driven, the air source selection is controlled in accordance with the
vehicle speed.
Operating conditions and control process are as follows:
1. The air source selection switch (recirculation switch) should be in AUTO position.
2. When the vehicle speed is 30 km/h or lower in fresh air mode, the air source door is open
20% of its maximum opening. If the vehicle speed is 50 km/h or more, then the air source
door is completely open.
4) Mode Control
▶ Manual control
You can choose a desired mode from the 5
modes by turning the mode as required.
The dial indicator for the selected mode comes
on to inform the operator.
01-26
▶ AUTO control
The air flow mode is controlled automatically in accordance with the vehicle indoor conditions.
But it is controlled as described below during initial driving (after overnight parking) in cold
weather:
5) Maximum Cooling/Heating Control (In AUTO Mode)

If the temperature is set to the lowest level (Lo) or highest level (Hi), the system will go into the
maximum cooling or maximum heating mode regardless of the sensor signals.
Set A/C Air flow Air source Blower Air mix door
temperature compressor mode voltage
LO ON Vent Recirculation 10.5 V Max. cooling position
HI OFF Foot Fresh air 10.5 V Max. heating position
6) A/C Control
▶ Manual control
Pressing the A/C switch or selecting defrost mode turns on the A/C.
▶ AUTO control
The A/C is controlled in accordance with the inner heat of the air conditioning system and
ambient temperature.
In cold weather, the compressor is turned off when the ambient temperature is low (2℃ or
below) for protection against damage.
6810-20 01-27
6) FATC Terminals
(1) Controller connector terminals
Connector A Connector B
(2) Description of terminals

Pin No. Function Pin No. Function
A1 P2 (REC) A19 PBR (Air mix motor)
A2 P2 (DEF) A20 PBR (Air source selection motor)
A3 P2 (COOL) A21 Blower motor operating signal
A4 P1 (HOT) A22 ILL (+)
A5 P1 (Vent) A23 Controller unit ground
A6 Vehicle speed signal B1 -
A7 REF (V) B2 -
A8 PTC ON B3 -
A9 IGN2 B4 Water temperature sensor signal
A10 Battery voltage B5 -
A11 P1 (FRE) B6 -
A12 Compressor operating signal B7 -
A13 Intake temperature signal B8 -
A14 Blower motor control signal B9 -
A15 Fan speed control B10 Sun-load sensor signal
A16 Air mix motor ground B11 Ambient temp. sensor signal
A17 A/C controller ground B12 -
A18 PBR (Mode motor)
01-28
7) Manual A/C Controller

(1) Controller connector terminals
Connector A Connector B
PCB: Connector added
▶ The ambient temperature sensor and its driving circuit have been fitted o the instrument
cluster of the vehicle manufactured from February 2012.
(2) Description of terminals

Pin No. Function Pin No. Function
A1 P2 (REC) A19 PBR (Air mix motor)
A2 P2 (DEF) A20 PBR (Air source selection motor)
A3 P2 (COOL) A21 Blower motor operating signal
A4 P1 (HOT) A22 ILL (+)
A5 P1 (Vent) A23 Controller unit ground
A6 Vehicle speed signal B1 -
A7 REF (V) B2 -
A8 PTC ON B3 -
A9 IGN2 B4 Water temperature sensor signal
A10 Battery voltage B5 -
A11 P1 (FRE) B6 -
A12 Compressor operating signal B7 -
A13 Intake temperature signal B8 -
A14 Blower motor control signal B9 -
A15 Fan speed control B10 Sun-load sensor signal
A16 Air mix motor ground B11 Ambient temp. sensor signal
A17 A/C controller ground B12 -
A18 PBR (Mode motor)
6810-00 01-29
1) Sensors & Actuators
Mode actuator Temperature actuator
Water temperature sensor Intake sensor

01-30
Air filter Intake actuator
PTC heater Blower motor

6810-00 01-31
2) Components
(1) Mode Actuator Assembly
Mode actuator
▶ Function
Mode actuator assembly

Controls the vent damper by the FATC command to control the air flow mode (Vent, Vent &
Foot, Foot, Defrost & Foot, Defrost).
▶ Maintenance

a. Turn the ignition switch to the "ON" position. Then, check the operation position of the
actuators by modes while changing the mode.
b. If the operating position is not correct, check the wiring for open circuit.
c. If the wiring is intact, replace the mode actuator assembly.
01-32
▶ Mode door actuator operating position
Bi-level
Foot
Vent
Defrost/Foot
Defrost
▶ Description on mode door actuator connector
Pin No. Function

1 P1
2 P2
3 Sensor ground
4 PBR
5 REF
6810-00 01-33
(2) Intake Actuator Assembly
Intake actuator
▶ Function
Intake actuator assy

Controls the air source door (intake) by the FATC command.
▶ Maintenance
Intake actuator assy
actuator each time the mode is changed.
c. If the wiring is intact, replace the intake actuator assembly.
01-34
▶ Intake actuator operation position
Recirculation
Fresh air
▶ Description on intake actuator connector
Pin No. Function

1 P1
2 P2
3 Sensor ground
4 PBR
5 REF
6810-00 01-35
(3) Temperature Actuator Assembly
Temperature actuator
▶ Function
Temperature actuator assy
Adjusts the temperature of the indoor air by controlling the temperature actuator assembly
position according to the FATC command.
▶ Maintenance
actuator each time the mode is changed.
c. If the wiring is intact, replace the temperature actuator assembly.
01-36
▶ Temperature actuator operation position
Cooling
Heating
▶ Description on temperature actuator connector
Pin No. Function

1 P1
2 P2
3 Sensor ground
4 PBR
5 REF
6810-00 01-37
(4) Incar Sensor
Incar sensor
▶ Mounting location
Located to the air intake on the front side of the FATC.
▶ Function
This sensor is a negative temperature coefficient (NTC) thermistor. It detects the interior air
temperature drawn through the senor inlet and sends the voltage value according to the
changed resistance to the FATC.
▶ Maintenance
If there is any fault in the incar sensor, check as described below:
a. Remove the incar sensor and measure the resistance between the two terminals on the
sensor connector.
(Specification: 2.186 ㏀ ± 3% at 25℃)
If the measured resistance is extremely high or low, replace the incar sensor.
b. If the measured value is out of the specified range, replace the incar sensor. If the
measured value is within the specified range, check as described below:
- Turn the ignition switch to "ON" position and measure the voltage between the pin no.
25 and 18 of the FATC connector. (Specification: approx. 1.7 V at 25℃)
- If the voltage value cannot be measured, check the wiring for open circuit. If the
measured value is within the specified range, replace the FATC.
01-38
(5) Water Temperature Sensor
Water temperature sensor
Located to the heater inlet pipe.
▶ Function
This sensor is a negative temperature coefficient (NTC) thermistor and detects the coolant
temperature to send the voltage value according to the resistance change to the FATC.
▶ Maintenance
If there is any fault in the water temperature sensor, check as described below:
a. Remove the water temperature sensor and measure the resistance between the two
terminals on the sensor connector.
If the measured resistance is extremely high or low, replace the water temperature sensor.
If the measured value is out of the specified range, replace the water temperature sensor. If
b. the measured value is within the specified range, check as described below:
- Turn the ignition switch to ON position and measure the voltage between the pin no. 15
and 11 of the FATC connector. (Specification: approx. 1.1 V at 25℃)
6810-00 01-39
(6) Intake Sensor
Intake sensor
Located to the side of the evaporator inside the A/C.
▶ Function
This sensor is a negative temperature coefficient (NTC) thermistor and detects the evaporator
temperature to send the voltage value according to the resistance change to the FATC.
▶ Maintenance
If there is any fault in the intake sensor, check as described below:
a. Remove the intake sensor and measure the resistance between the two terminals on the
sensor connector.
(Specification: 8 ㏀ ± 1% at 1℃)
If the measured resistance is extremely high or low, replace the intake sensor.
b. If the measured value is out of the specified range, replace the intake sensor. If the
measured value is within the specified range, check as described below:
and 18 of the FATC connector. (Specification: approx. 5.1 V at 1℃)
01-40
(7) MOS Module
MOS module
The MOS module controls the fan speed. It receives the fan speed control signal from the A/C
control unit to control the rotation speed of the blower motor by adjusting the current applied to
the base of the power transistor.
▶ Maintenance
If there is any fault in the MOS module (DTC 6), check as described below:
- Turn the ignition switch to ON position.
- Measure the voltage between the terminals of the blower motor while changing the fan
speed from the lowest level to the highest level.
- The specified voltage value in each stage:
Step 1 2 3 4 5 6 7
Control FATC 4V 5V 6.5 V 8.5 V 10.5 V 11 V to -
voltage Battery voltage
Manual 4V 5V 6V 7.5 V 9V 10.5 V 11 V to

Battery voltage
- If the measured value is out of the specified range, check the wiring for open circuit. If the
wiring is intact, replace the resistor.
6810-00 01-41
(8) Ambient Temperature Sensor
Ambient temperature
sensor
Located to the upper center side of the front bumper.
▶ Function
This sensor is a negative temperature coefficient (NTC) thermistor and detects the ambient
temperature to send the voltage value according to the resistance change to the A/C control
unit.
▶ Maintenance
If there is any fault in the ambient temperature sensor, check as described below:
a. Remove the ambient temperature sensor and measure the resistance between the two
terminals on the sensor connector.
If the measured resistance is extremely high or low, replace the ambient temperature sensor.
If the measured value is out of the specified range, replace the ambient temperature sensor. If
b. the measured value is within the specified range, check as described below:
- Turn the ignition switch to ON position and measure the voltage between the pin no.
B11 and A16 of the A/C control unit connector. (Specification: approx. 1.7 V at 25℃)
- If the voltage cannot be measured, check the wiring for open circuit. If the result is as
specified, replace the A/C control unit.
01-42
(9) Sun-load Sensor
Sun-load sensor
Located on the left side of the instrument panel.
▶ Function
Detects the sun-load enters to the interior through the windshield with a photo diode.
Then it converts the sun-load to current value and sends to the FATC.
* Photo diode
It uses the characteristic that the current is changed according to the amount of light on
the photosensitive surface.
▶ Maintenance
If there is any fault in the sun-load sensor, check as described below:
a. Remove the sun-load sensor and measure the current between the terminals with the
sensor exposed to direct sunlight.
b. Measure the current again under shade. It is normal if the measured value is less than the
measured value in direct sunlight. Check the followings:
and 18 of the FATC connector.
(Specified value: approx. 1.7 V in direct sunlight, approx. 3.1 V under shade)
6810-15 01-43
PTC heater
This system is mounted in the heater air outlet and heats the air which flows to the passenger
room.
Because the PTC system is heated by the electrical power, the electric load and alternator
capacity is greater than the conventional one. For example the alternator capacity of the vehicle
with PTC is 140 A while the vehicle with FFH is only 115 A. The PTC is not operated when a) the
engine is cranking, b) the battery voltage is below 11 V, c) the glow plug is being preheated.
01-44
▶ PTC Operating (ON) Condition
Item PTC (Positive Temperature Coefficient) heater

Heating type Air heating type
Heating efficiency Excellent
Material Ceramic PTC (BaTio2)

Weight Excellent
Durability Excellent
Safety Excellent
1. Stable output regardless of voltage changes

Advantages 2. Blocks the over current with switch effect of PTC element
3. Excellent durability of heating element against high current
▶ PTC Operating (ON) Condition

1. 1st step (Initial PTC operating condition)
- When coolant temperature is less than 15℃, PTC is operated (ON).
- When coolant temperature is 15℃ or higher, 2 conditions described below must be satisfied
for PTC operation.
2. 2nd step (Coolant temperature: 15℃)

- When coolant temperature is 65℃ or lower and intake temperature is -10℃ or lower, PTC
is operated (ON).
- When coolant temperature is between 60℃ and 65℃ and intake temperature is between -
10℃ and 0℃, PTC is operated (ON).
- When coolant temperature is 60℃ or lower and intake temperature is between 0℃ and 5℃
or lower, PTC is operated (ON).
▶ PTC "OFF" Condition
- Air conditioner blower switch OFF

- Ambient temperature sensor error (wiring short or open)
- When the engine is cranking
- When the battery voltage is 11 V or less
- When the glow plug is in preheating (Glow indicator ON)
6810-20 01-45
1) Overview
The FATC has a self diagnosis function that can diagnose the system by itself.
Before checking each component, be sure to check the default code by using self diagnosis
function.
2) Symptoms In Event Of Faults

If there is any fault in the auto temperature control system, the indicator on the recirculation switch
or A/C switch is illuminated.
indicator comes on
A/C switch indicator

comes on
3) How to Start Self Diagnosis

Turn the ignition switch to ON from OFF and press the A/C switch for more than 5 seconds within
10 seconds provided that the fan speed dial and the mode dial are in AUTO position. Then the
A/C switch indicator flashes 3 times which means the self diagnosis started.
The result for the diagnosis is indicated by the indicators on the recirculation switch and the A/C
switch.
indicator flashes 3
times
Press the A/C switch for 5 A/C switch

Mode dial in
seconds or longer (Fan speed indicator flashes 3
AUTO position
dial in AUTO position). times
01-46
4) Self Diagnosis
The system is normal if the indicators on the recirculation switch and A/C switch flashes. If those
indicators are illuminated, then the system is malfunctioning.
indicator flashes:
Normal

flashes: Normal
▶ 1st step (Automatic diagnosis)

Once the self diagnosis is started, the faults of the 4 sensors (ambient temperature sensor,
water temperature sensor, incar sensor, intake sensor, water temperature sensor) and 3
actuators (mode actuator, intake actuator, temperature actuator) are checked.
The recirculation switch indicator comes on when the actuator is malfunctioning (if the
indicator flashes, the actuator is normal).
The A/C switch indicator comes on when the sensor is malfunctioning (if the indicator flashes,
the sensor is normal).
flashes: Normal Comes on: Faulty

actuator
flashes: Normal Comes on: Faulty

sensor
6810-20 01-47
▶ 2nd step (Manual diagnosis)

When the sensor is malfunctioning, the sensor is diagnosed manually.
Turn the blower dial to AUTO position, and turn the mode dial to vent, bi-level, foot,
defrost/foot, defrost, in sequence. If the A/C switch indicator is illuminated then the sensor is
malfunctioning. If the indicator flashes then the sensor is normal.
Mode Diagnosed component Indicator for result

Vent Sun-load sensor
Bi-level Ambient temperature sensor
Foot Incar sensor A/C switch indicator
Defrost/Foot Intake sensor

Defrost Water temperature sensor

comes on: Malfunctioning

flashes: Normal
Diagnose each sensor while turning
the mode dial to vent, bi-level, foot,
defrost/foot, defrost, in sequence.
Turn the blower dial to
AUTO position.
01-48
▶ 3rd step (Manual diagnosis)

When the actuator is malfunctioning, it is diagnosed manually.
Turn the blower dial to 1 stage or higher position, and turn the mode dial to vent, bi-level, foot,
in sequence. If the recirculation switch indicator is illuminated then the actuator is
malfunctioning. If the indicator flashes, the sensor is normal. But, if it comes on, the sensor is
faulty.
Mode Diagnosed component Indicator for result

Vent Mode
Bi-level Temperature Recirculation switch indicator
Foot Intake
comes on: Malfunctioning
flashes: Normal Diagnose each actuator while
turning the mode dial to vent,
bi-level, foot, in sequence.
* For the 2nd and 3rd steps excepting for 1st (automatic diagnosis), the diagnosis start
conditions should be met by manual control.
(5) Finishing Diagnosis

Pressing the recirculation switch or restarting the engine stops the diagnosis.
Press the recirculation

switch to finish.
6810-20 01-49
- Disconnect the negative battery cable.
Heater and A/C control

assembly
1. Remove the passenger side fascia panel.
2. Open the glove box and unscrew the two

mounting screws to remove the side
fascia molding.
01-50
3. Unscrew the 5 side fascia panel assembly

mounting screws to remove the side
fascia panel.
4. Remove the side fascia panel assembly.
5. Unscrew the two mounting screws on the

cluster fascia panel assembly.
6. Detach the cluster fascia panel assembly

from the instrument panel.
6810-20 01-51
7. Detach the center fascia molding from the

instrument panel.
Center fascia fixing clip
8. Disconnect the ignition switch connector

(A) and remove the center fascia molding
assembly.
9. Unscrew the one mounting screw on the

center fascia panel assembly.
10.Remove the center fascia panel assembly.
Center fascia panel

fixing clip
01-52
11.Unscrew the four audio mounting screws

(A).
12.Lift out the audio and disconnect the

connectors.
(A) Wiring connector

(B) USB connector
(C) AUX connector
(D) Antenna
13.Disconnect the switch module connector

under the audio.
14.Unscrew the 4 mounting screws (A) for

the heater and A/C control.
6810-20 01-53
15.Remove the heater and A/C control

assembly.
16.Disconnect the heater and A/C control

assembly connectors (A and B).
17.Disconnect the connectors under the

heater and A/C control assembly.
(A) AUX connector

(B) USB connector
(C) Cigar lighter connector
18.Remove the heater and A/C control

assembly.
01-54
19.Unscrew the 4 mounting screws located

behind the heater and A/C control
assembly.
20.Installation is in the reverse order of

removal.
6810-00 01-55
- Disconnect the negative cable from the battery and remove the instrument panel
assembly.
- Drain the refrigerant before removing the A/C module assembly. The collected
refrigerant should be disposed of at designated disposal sites.
- Drain the coolant in the radiator.
A/C module assembly
1. Disconnect the heater hoses (inner/outer)

from the engine compartment.
01-56
2. Remove the cowl and unscrew the 3

wiper motor assembly mounting bolts
(10 mm) to remove it.
3. Unscrew the two mounting bolts (10 mm).
4. Lift the vehicle with a lift and unscrew the

two mounting nuts securing the insulator to
the engine compartment.
5. Unscrew the A/C joint pipe mounting nut

(10 mm).
6810-00 01-57
6. Remove the instrument panel. Refer to "Removal and Installation" section of "Body Interior".
7. Remove the mountings from the instrument frame.
Driver side 4 cross member mounting Passenger side

4 mounting bolts bolts (12 mm) 4 mounting bolts
(12 mm) One mounting screw (B) (12 mm)
One duct mounting screw(A)

One duct mounting screw (A),
2 mounting bolts (B, 12 mm)
One ground mounting bolt Two mounting bolts
One ground mounting bolt
(10 mm) (B, 12 mm)
(C,10 mm)
01-58
8. Disconnect the connectors of the body

main wiring connector assemblies.
9. Disconnect the wiring connector.
10.Remove the mountings securing the

wirings.
11.Remove the passenger side mountings

securing the wirings.
6810-00 01-59
12.Remove the instrument frame.
13.Disconnect the PTC heater assembly

connector.
14.Disconnect the hose connected to the A/C

module.
15.Remove the A/C module.

01-60
16.Installation is in the reverse order of

removal.
6810-12 01-61
1. Remove the crash pad side cover

assembly.

lower main panel assembly.
01-62
3. Detach the lower main panel assembly to

remove the connection. Then, remove the
Refer to "Removal and Installation" section

of "Body Interior".
4. Remove the mode actuator connector.
5. Unscrew the two mode actuator mounting

screws.
6. Remove the mode actuator assembly.

6810-12 01-63
7. Installation is in the reverse order of

removal.
01-64

assembly.

6810-11 01-65


of "Body Interior".
4. Remove the temperature actuator

connector.
5. Unscrew the two temperature actuator

mounting screws.
6. Remove the temperature actuator assembly.

01-66

removal.
6810-02 01-67

- Remove the instrument panel.
Intake actuator
1. Remove the intake actuator connector.
2. Unscrew the two intake actuator mounting

screws.
01-68
3. Remove the intake actuator assembly.

removal.
6810-00 01-69

- Remove the lower main panel assembly.
Water temperature sensor
1. Disconnect the water temperature sensor

connector.
2. Unscrew the one mounting screw.

01-70
3. Remove the water temperature sensor.

removal.
6810-24 01-71

- Remove the A/C module.
Intake sensor
1. Remove the intake sensor connector.
2. Disconnect the mode actuator connector,

intake actuator connector and sensor
wiring from the A/C module, and remove
the blower assembly and the heater &
evaporator assembly.
01-72
3. Separate the upper and lower parts of the

heater and evaporator assembly.
4. Remove the mountings on the heater and

evaporator assembly.
5. Remove the intake sensor located on the

evaporator core.

removal.
6810-06 01-73
MOS module
1. Remove the MOS module connector.
2. Unscrew the two mounting screws.

01-74
3. Remove the MOS module.

removal.
6810-05 01-75
- Disconnect the negative cable from the battery.

Blower motor
1. Disconnect the blower motor connector.
2. Unscrew the three mounting screws.

01-76
3. Remove the blower motor.

removal.
6810-03 01-77
Air filter assembly
1. Open the glove box, remove the locking

devices in sequence and lower them down.
2. Press the air filter cover mounting holder

to remove the cover.
01-78
3. Remove the air filter.

removal.
6810-15 01-79
PTC heater

assembly.

01-80


of "Body Interior".
4. Disconnect the PTC heater connector.
5. Unscrew the two mounting screws for the

PTC heater.
6. Remove the PTC heater.

6810-15 01-81

removal.

Air Conditioning

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GENERAL INFORMATION REMOVAL AND INSTALLATION

1. SPECIFICATION.................................... 3 6810-20 FATC SELF DIAGNOSIS............. 45

Ambient temperature sensor signal Blower max signal wiring added

Manual A/C: Wiring pin added to controller assembly connector

2) Manual A/C Controller

Pin No. Function

Line & port

Low pressure hose

High pressure hose

A/C condenser & receiver drier A/C compressor

FATC Incar sensor

2. HEATER AND A/C CONTROL

Temperature dial Mode dial Fan speed dial

Recirculation switch A/C switch

- When you press this switch,

- The air flow direction can be controlled by turning the dial.

Airflow is changed Use this switch to remove for

▶ Fan speed dial

Fan speed dial

2) Manual A/C Control

Fan speed dial Mode dial Temperature dial

A/C switch Recirculation switch

▶ Fan speed dial

Fan speed dial

Face/Foot-Level Foot-Level (foot mode)

3. A/C COOLING CYCLE

(4) Expansion valve

3) Description for Each Cycle

4. A/C COOLING CIRCUIT

1. Blower assy 12.Mode actuator assembly

1. Condenser assy 12.Liquid & suction pipe assy

Recirculation switch Dial indicator

Temperature dial Switch indicator

Mode dial In-car sensor

Fan speed dial (Blower dial)

1) FATC Input/Output Diagram

▶ A/C compressor control by engine ECU

(2) Blower control

Blower step Blower motor voltage (V)

▶ Control in relation to sun-load

▶ Control for defrosting

▶ Heating start control

▶ Cooling start control

▶ Control for defrosting

3) Intake Fresh/Recirculation Control

▶ Control by vehicle speed (heating)

5) Maximum Cooling/Heating Control (In AUTO Mode)

(2) Description of terminals

7) Manual A/C Controller

PCB: Connector added

(2) Description of terminals

1) Sensors & Actuators

Mode actuator Temperature actuator

Water temperature sensor Intake sensor

Air filter Intake actuator

PTC heater Blower motor

Mode actuator assembly

Mode actuator assembly

▶ Mode door actuator operating position

▶ Description on mode door actuator connector

Pin No. Function

(2) Intake Actuator Assembly

Intake actuator assy

▶ Intake actuator operation position