Hyundai Excel X2 1989-1998 Air Conditioning

AIRCONDITIONINGSYSTEM

Return To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

HEATER CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 12

HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 19

COMPRESSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4

EVAPORATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

CONDENSER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7

CONDENSER FAN & RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 49

BLOWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0

ACCUMULATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 52

GENERAL

SPECIFICATION (H.C.C)

Heater assembly

TypeHeating capacity

Air conditionerCooling capacity

CompressorModelNo. of cylinders and displacement CC/RevMaximum allowable continuous rpm

Magnetic clutchVoltage, power consumption

ControlIdle up device (FBC only)

Protective equipmentClutch cycling switch

Cut out pressureMax. cut in pressureMin. difference pressure

Pressure relief valveRelief pressureExhaust flowResealed pressure

Refrigerant and quantity gr. (oz, lb.)

3,800 Kcal/h (15,000 B.T.U/h)

3,300 Kcal/h (13,000 B.T.U/h)

SD-7097 cylinders, 1556000

DC12V, 49W

900 ± 25 rpm

167 kPa (1.7 ± 0.1 kg/cm2, 24 psi)324 kPa (3.3 kg/cm2, 47 psi)118 kPa (1.2 kg/cm2, 17 psi)

31.6 kg/cm2 (449 psi) MIN., 42.18 kg/cm2 (560 psi) MAX.Min. 113.2 L/MIN. at 42.18 kg/cm2 (560 psi)Min. 28.2 kg/cm2 (401 psi)R-12 850-900 (30-32, 1.87-1.92)

SERVICE STANDARDS

Amount of deflection of V belt mm (in.)Engine idle speedAir gap mm (in.)

8.0-10.0 (0.32-0.40)700±50 rpm (without MPI)0.4-0.8 (0.016-0.032)

LUBRICANTS

Recommended lubricant Quantity

Heater control leverCompressor oil

Multipurpose greaseSuniso 5GS or equivalant

As required240 cc (8.1 fl oz)

9 7 - 2

GENERAL

SPECIAL TOOLS

9 7 - 3

GENERAL

TROUBLESHOOTING

INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM

TEST STEP RESULT ACTION TO TAKE

A1 VERIFY THE CONDITION

Check system operation System cooling INSTRUCT vehicle ownerproperly on proper use of the

system

System not cooling GO to A2Properly

A2 CHECK A/C COMPRESSOR CLUTCH

Does the A/C compressor clutch engage? Yes

No

GO to A3

REFER to clutch circuitdiagnosis in this section

A3 CHECK OPERATION OF COOLING FAN

Check that the cooling fan runs when the A/C Yescompressor clutch is engaged

No

GO to A4

Check for cooling fanelectric circuit

A4 COMPONENT CHECK

o Under-hood check of the following: OK but still not GO to A6Loose, missing or damaged compressor drive belt. coolingLoose or disconnected A/C clutch or clutch cycling Not OK

REPAIR AND GO to A5pressure switch connectors.Disconnected resistor assembly.Loose vacuum lines or misadjusted control cables

o Inside vehicle check for:Blown fuse or improper blower motor operation.Vacuum motors/temperature door movement-fulltravel.Electrical and vacuum connections.

A5 CHECK SYSTEM

Check system operationOK Condition Corrected

GO to A1

Not OK GO to A6

9 7 - 4

GENERAL

INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM(Continued)

TEST STEP RESULT ACTION TO INTAKE

A6 CHECK COMPRESSOR CLUTCH

Use refrigerant system clutch cycle rate and timing Compressor cycles GO to A7

evaluation charts. very rapidly

Prepare the car as follows (1 second on)

1. Hook up the manifold gauge set (1 second off)

2. Set Function lever at max A/C3. Set blower switch on high

Compressor runs GO to A8

4. Set temperature lever full coldcontinuously (normal

5. Close doors and windowsoperation in ambient

6. Use a thermometer to check temperature at centertemperature above

discharge register. Record outside temperature.27°C. (80°F.)

7. Run engine at approximately 1500 RPM withdepending on

compressor clutch engaged.humidity conditions)

8. Stabilize with above conditions for 10-15 minutes. Compressor cycles GO to A7

Check compressor clutch ON/OFF time. Refer to slowcharts for normal Clutch cycling timing rates.

A7 CHECK CLUTCH CYCLING PRESSURE SWITCH

Bypass the clutch cycling pressure switch with a jumper Outlet line same REPLACE clutch cycling

wire. temperature pressure switch. Do not

Compressor on continuously. approximately -2°C. discharge system

Feel evaporator inlet and outlet lines. 4°C. (28°F. - 40°F.) Switch fitting has

or slightly colder Schrader valve GO to A8

than inlet line (afterfixed orifice)

Inlet line warmer or GO to A9(after fixed orifice)colder than outletline

9 7 - 5

GENERAL

INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM(Continued)


A8 CHECK SYSTEM PRESSURES

Compare readings with normal system pressure ranges. Clutch cycles within System OK

limits. System pres- GO to A1sure within limits

Compressor runs GO to A11continuously (normaloperation in ambienttemperature above27°C (80°F.)depending onhumidity conditions).

Compressor cycles REPLACE clutch cyclinghigh or low ON pressure switch. Do notabove 359 kPa discharge system(52 psi) OFF below Switch timing has144 kPa (21 psi). Schrader valve CHECK

system OK.GO to A1NOT OK.GO to A9

A9 CHECK SYSTEM

Check system for leaks Leak found REPAIR, discharge, evac-uate and charge system.System OKGO to A1

No Leak found Low refrigerant chargeor moisture in system.Discharge, evacuate andcharge system. SystemOK

A10 CHECK CLUTCH CYCLING

Disconnect blower motor wire and check for clutch Clutch cycles OFFcycling off at 144 kPa (21 psi) (suction pressure) at 144-179 kPa

(21-26 psi)

Connect blower motorwire.System OKGO to A1

Pressure falls below REPLACE clutch cycling144 kPa (21 psi) pressure switch. Do not

discharge system.Switch fitting hasSchrader valve. SystemOK.GO to A1

9 7 - 6

GENERAL

COMPRESSOR CIRCUIT CLUTCH DIAGNOSIS


B1 CHECK SYSTEM OPERATION

o Turn the blower switch ON. Clutch and fan operate System OKo Depress the A/C button.o Turn the ignition switch to the RUN position.

Clutch and fan do not GO to B2

o Compressor clutch should engage and engineoperate

cooling fan should operate. Only fan operates GO to B5

B2 CHECK FOR VOLTAGE

o Check for voltage at circuit wire at the clutch Voltage presentcycling pressure switch connector.

No voltage

B3 BY-PASS PRESSURE SWITCH

o Disconnect the connector at the clutch cycling OKpressure switch

o Jump connector pins. Not OKo Clutch should engage.

GO to B3

GO to A1

GO to B4

GO to B5

B4 CHECK SYSTEM PRESSURE

o Connect the manifold gauge set and check the Pressure above 55 psi REPLACE clutch cyclingsystem pressure. pressure switch GO to A1

Pressure below 55 psi CHECK refrigerant(ambient temperature system for leaks.above 50°F) REPAIR and CHARGE

system as necessaryGO to A1.

B5 CHECK VOLTAGE AT CLUTCH

o Check for voltage at the clutch field coil.

B6 CHECK VOLTAGE AT BATTERY

o Check for voltage at the battery.

B7 CHECK FUSE

Voltage present

No voltage

Voltage Present

No voltage

GO to B7

GO to B6

GO to B7

Check for low battery voltage.SERVICE as necessary.GO to A1.

o Check fuse in panel for continuity. OK

Not OK

GO to B1.

CHECK for short.SERVICE as necessary.REPLACE fuse. GO to B1.

9 7 - 7

GENERAL

SERVICE ADJUSTMENT

ADJUSTMENT OF FAST IDLE CONTROL DEVICE(without MPI) (F.I.C.D)

The vacuum system is designed to actuate the F.I.C.D. whichraises the idle speed of the engine to ensure better cooling whenthe car is stationary.

1. Warm up the engine.2. Make sure the engine is at the correct idle speed with the

air conditioner in the “OFF” position.3. Set the engine speed to the specified rpm with the air

conditioner in the “ON” position.

Specified rpm : 900 ± 25 rpm

4. Depress and release the accelerator pedal several times, andmake sure that the engine speed returns to the specifiedrpm.

9 7 - 8

GENERAL

CHECKING AND ADJUSTING THE A/CCOMPRESSOR BELT

After installation, check the following points:1. Check for abnormal vehicle performance.2. Check the magnetic clutch for operation (without turning on

the compressor).3. Check for any parts left unmounted or any tool left behind

in the vehicle.4. Check the belt for proper tension.

Belt deflectionAir conditioner compressor belt . . . . . . . . . . . . . . . . . . . . . . .

8.0-10.0 mm (0.34-0.42 in.)

5. Charge the system.6. Check the idle speed.7. Test the system for proper operation.

9 7 - 9

GENERAL

VACUUM SYSTEM SYMPTOM AND PROBABLE CAUSE

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GENERAL

Symptom

On “FLOOR” position. All air throughdefroster or DEF/FLOOR.

Probable cause

o Blue and/or red vacuum hose pinched or disconnected atvacuum motor.

o Black source hose pinched or disconnected at the connector.o Engine compartment A/C source hose pinched or discon-

nected at the vacuum manifold.o Defective vacuum motor.

On “DEF/FLOOR” position. All air throughdefroster.

o Blue hose pinched or disconnected at vacuum motor.o Blue vacuum hoses installed improperly (reversed).o Black source hose pinched or disconnected at the connector.o Engine compartment A/C source hose pinched or discon-


On “PANEL VENTS” position. All airthrough defroster.

o Yellow vacuum hose pinched or disconnected at vacuummotor.



On “PANEL/FLOOR” position. All airthrough defroster or panel

o Yellow vacuum hose pinched or disconnected at vacuummotor.

o Blue hose pinched or disconnected at vacuum motor.o Black source hose pinched or disconnected at the connector.o Engine compartment A/C source hose pinched or discon-


On “DEF” position. (No vacuum)On “RECIRC” position. All air throughfresh.

o White vacuum hose disconnected at the connector or recircduct vacuum motor.



9 7 - 1 1

HEATER CONTROL ASSEMBLY

HEATER CONTROL ASSEMBLY

COMPONENTS

REMOVAL AND INSTALLATION

1. Pull out the ash tray and remove the bolt.2. Pull out the heater control panel assembly and then

disconnect the A/C switch, defrostor and cigar lighterconnectors.

3. Remove the heater control assembly mounting bolts.4. Pull out the heater control assembly and then disconnect the

blower motor switch connector, vacuum connector and thetemperature control cable.

5. Installation is the reverse of removal.

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HEATER

COMPONENTS VACUUM TYPE

9 7 - 1 3

HEATER

COMPONENTS LEVER TYPE

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VENTILATORS

REMOVAL

1. Disconnect the negative terminal at the battery.2. Drain the coolant from the radiator.3. Remove the heater hoses and the evaporator drain hose.4. Using the special tool (09977-33600 A/B), remove the

suction and the liquid lines.

5. Remove the console assembly (Refer to BODY GROUP).6. Remove the glove box assembly, main lower crash pad

assembly and lower crash pad center facia panel assembly(Refer to BODY GROUP).

7. Remove the heater control assembly.

8. Remove the lower crash pad center skin assembly (Refer toBODY GROUP).

9. Remove the crash pad center support bracket assembly(Refer to BODY GROUP).

10. Remove the evaporator unit assembly.

11. Remove the rear heating joint duct assembly.12. Remove the heater unit assembly.

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HEATER

INSPECTION

1. Check the linkage mechanism for operation.2. Check the heater core for restrictions or leakage.

INSTALLATION

1. Installation is the reverse of the removal procedures.

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VENTILATORS

V E N T I L A T O R S

COMPONENTS

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HEATER


1. Remove the main crash pad assembly (Refer to BODYGROUP)

2. Remove the side air vent louver duct assembly (LH/RH).

3. Remove the side air vent hose assembly (LH/RH).4. Remove the side air vent louver assembly (LH/RH).

5. Remove the heater connection assembly.6. Remove the defroster nozzle assembly.7. Remove the side defroster nozzle assembly (LH/RH).8. Remove the crash pad upper cover assembly.

9. Remove the rear heating joint duct assembly and rearheating side duct assembly (LH/RH).

10. Installation is the reverse of removal procedures.

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AIR CONDITIONER SYSTEM

AIR CONDITIONER

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

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AIR CONDITIONER SYSTEM SERVICE

CAUTIONS

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Never open or loosen a connection before discharging thesystem.When loosening a connection, if any residual pressure isevident, allow it to bleed off before opening the fitting.A system which has been opened to replace a componentor one which has discharged must be evacuated beforecharging.Immediately after disconnecting a component from thesystem, seal the open fittings with a cap or plug.Before disconnecting a component from the system, cleanthe outside of the fittings thoroughly.Do not remove the sealing caps from a replacementcomponent until it is ready to be installed.Refrigerant oil will absorb moisture from the atmosphere ifleft uncapped. Do not open an oil container until ready touse, and install the cap immediately after using. Store oilonly in a clean, moisture-free container.Before connecting an open fitting, always install a newsealing ring. Coat the fitting and seal with refrigerant oilbefore making the connection.When installing a refrigerant line, avoid sharp bends.Position the line away from the exhaust or any sharp edgeswhich may chafe the line.Tighten fittings only to the specified torque. The fittings usedin the refrigerant system should not be over-tightened.When disconnecting a fitting, use a wrench on both sidesof the fitting to prevent twisting the refrigerant lines.Do not open a refrigerant system or uncap a replacementcomponent unless it is as close as possible to roomtemperature. This will prevent condensation from forminginside a component which is cooler than the surrounding air.Whenever a major component such as an evaporator,condenser, compressor, or refrigerant line is replaced, it ismandatory that the accumulator/drier also be replaced.Keep service tools and the work area clean. Contaminationof a refrigerant system through careless work habits mustbe avoided.

9 7 - 2 0


AIR CONDITIONER SYSTEM SERVICE

SAFETY PRECAUTIONS

1. R-12 liquid refrigerant is highly volatile. A drop on the skinof your hand could result in localized frostbite. Whenhandling the refrigerant, be sure to wear gloves.

2. If the refrigerant splashes into your eyes, wash them withclean water immediately. It is standard practice to weargoggles or glasses to protect your eyes, and gloves to protectyour hands.

3. The R-12 container is highly pressurized. never leave it ina hot place, and check that the storage temperature is below52°C (126°F).

4. A halide leak detector is often used to check the system forrefrigerant leakage. Bear in mind that R-12, upon cominginto contact with flame (this detector burns propane toproduce a small flame), produces phosgene, a toxic gas.

INSTALLATION OF MANIFOLD GAUGE SET

1. Close both hand valves of the manifold gauge.2. Install the charging hoses of the gauge set to the fittings.

Connect the low-pressure hose to the low-pressure serviceport, and the high-pressure hose to the high-pressure serviceport.Tighten the fittings by hand.

NOTEFittings for attaching the manifold gauge set are locatedon the compressor discharge hose and the accumulator.

DISCHARGING THE REFRIGERATIONSYSTEM

1. Connect the manifold gauge set to the system.2. Place the free end of the center hose on a shop towel.3. Slowly open the high-pressure hand valve to adjust the

refrigerant flow. Open the valve slightly.

NOTE:If refrigerant is allowed to escape too fast, compressor oilwill be drawn out of the system.

4. Check the shop towel to make sure no oil is beingdischarged. If oil is present, partially close the hand valve.

5. After the manifold gauge reading drops below 434 kPa (3.5kg/cm2, 50 psi), slowly open the low-pressure hand valve.

6. As the system pressure drops, gradually open both the highand the low-pressure hand valves until both gauges read 1kPa (0 kg/cm2, 0 psi).

9 7 - 2 1


EVACUATING REFRIGERANT SYSTEM

NOTE:It is necessary to evacuate the air conditioning system anytime the system has been opened. Evacuation is necessary topurge the system of all air and moisture that may have beenallowed to enter the unit.After installation of a component, the system should beevacuated for approximately 15 minutes. A component inservice that has been opened for repair should be evacuatedfor 30 minutes.

1. Engine should be off.2. Connect a manifold gauge set to the service ports. Close both

high and low pressure valves.3. Make sure the refrigerant has been discharged from the

system.4. Connect the center hose of the gauge set to the vacuum

pump inlet.5. Start the vacuum pump and then open the high and low

manifold pressure valves.6. After about ten minutes, check that the low pressure gauge

reads more than 94.39 kPa (0.96 kg/cm2, 13.7 psi) vacuum.If negative pressure can not be obtained, there is a leak inthe system. In this case, repair the leak as described in thefollowing.1) Close both the manifold valves and stop the vacuum

pump.

2) Charge the system with a can of refrigerant [about 0.4kg (0.9 lb)]. Refer to Charging Refrigerant.

3) Check for refrigerant leakage with a leak detector.4) Repair any leakage found. Refer to Checking Refrigerant

Leaks.5) Discharge the system again, and then evacuate the

system.7. Start the vacuum pump.8. Open both manifold pressure valves to obtain 94.39 kPa

(0.96 kg/cm2, 13.7 psi) of vacuum.9. After the low pressure manifold gauge indicates as close to

94.39 kPa (0.96 kg/cm2, 13.7 psi) as possible, continueevacuating for 15 minutes.

10. After evacuating for 15 minutes, close both manifoldpressure valves and stop the vacuum pump. Disconnect thehose from the vacuum pump. The system is now ready forcharging.

9 7 - 2 2


HANDLING REFRIGERANT SERVICE TAPVALVE

1. Before connecting the valve to the refrigerant container, turnthe handle fully counterclockwise.

2. Turn the adapter counterclockwise until it reaches its highestposition.

3. Connect the center hose to the valve fitting. Turn the adapterfully clockwise by hand.

4. Turn the handle clockwise to make a hole in the sealed top.5. Turn the handle fully counterclockwise to fill the center hose

with air. Do not open the high and low-pressure hand valves.6. Loosen the center hose nut connected to the center fitting

of the manifold gauge.7. Allow air to escape for a few seconds, and then tighten the

nut.

CHARGING REFRIGERANT SYSTEM(VAPOR)

NOTEThis step is to charge the system through the low pressureside with refrigerant in a vapor state. When the refrigerantcontainer is placed rightside up, refrigerant will enter thesystem as a vapor.

1.

2 .

3.

4.

5.

Install the refrigerant can tap valve as described in Handlingthe Refrigerant Service Tap Valve section.Open the low pressure valve. Adjust the valve so that thelow pressure gauge does not read over 412 kPa (4.2 kg/cm2,60 psi).Put the refrigerant in a pan of warm water (maximumtemperature 40°C or (104°F) to keep vapor pressure in thecontainer slightly higher than vapor pressure in the system.Run the engine at fast idle, and operate the air conditioner.

NOTE:Be sure to keep the container upright to prevent liquidrefrigerant from being charged into the system throughthe suction side, resulting in possible damage to thecompressor.

Charge the system to the specified amount. Then, close thelow pressure valve.

Specified amount: 850-900 g (1.87-1.92 lb)

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When refrigerant charging speed is slow, immerse therefrigerant can in water, heated to a temperature of about40°C (104°F).

WARNINGo Under no circumstances should the refrigerant can be

warmed in water heated to a temperature of over 52°C(126°F).

o A blow torch or stove must never be used to warm up thecan.

CHARGING REFRIGERANT SYSTEM(LIQUID)

NOTEThis step is to charge an empty system through the highpressure side with refrigerant in a liquid state. When therefrigerant container is held upside down, refrigerant will enterthe system as a liquid.

CAUTION:Never run the engine when charging the system through thehigh pressure side.Do not open the low pressure valve when the system is beingcharged with liquid refrigerant.

1. Close both the high and low pressure valves completely afterthe system is evacuated.

2. Install the refrigerant can tap valve as described in “HandlingRefrigerant Service Tap Valve” section.

3. Open the high pressure valve fully, and keep the containerupside down.

4. Charge the system to the specified amount by weighing therefrigerant with a scale. Overcharging will cause dischargepressure (high side) to rise. Then, close the high pressurevalve.

Specified amount: 850-900 kg (1.87-1.92 lb)

NOTE:If the low pressure gauge does not show a reading, thesystem is restricted and must be repaired.

5. After the specified amount of refrigerant has been chargedinto the system, close the manifold gauge valve.

6. Check that there are no leaks in the system with a leakdetector. Refer to Checking Refrigerant Leaks.

NOTE:Conducting a performance test prior to removing themanifold gauge is a good service operation.

9 7 - 2 4

Immerse in waterheated to about40°C (104°F) for ashort time.


COMPRESSOR OIL LEVEL CHECK

The oil used to lubricate the compressor circulates in the systemwhile the compressor is operating. Whenever replacing anycomponent of the system or when a large amount of gas leakageoccurs, add oil to maintain the original total amount of oil.

Total amount of oil in the system: 240CC (8.1 fl.oz)

Handling of Oil

1. The oil should be free from moisture, dust, metal fillings, etc.2. Do not mix oils.3. The moisture content in the oil increases when exposed to

the air for prolonged periods.After use, seal the container immediately.

Oil Return Operation

Before checking and adjusting the oil level, operate thecompressor at engine idle speed, with the controls set formaximum cooling and high blower speed, for 20 to 30 minutesin order to return the oil to the compressor.

Checking and Adjusting a Used Compressor

The compressor oil should be checked in the following order:1. After the oil return operation, stop the engine, discharge the

refrigerant and then remove the compressor from thevehicle.

2. Drain the oil from the system line connecting ports.

Oil is sometimes hard to drain out when the compressoris cool. Drain oil while the compressor is warm[maintained at 40°-50°C (104-122°F)].

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3. Measure the amount of the oil removed. If the amount isless than 70cc (2.1 US fl oz, 2.5 Imp fl oz), some oil mayhave leaked out. Conduct leak tests at the connections, andif necessary, repair or replace faulty parts.

4. Check the purity of the oil and then adjust the oil levelfollowing the procedure below.1) If the oil is clean

Unit: cc (US fl oz, Imp fl oz)

Amount of oil drained Adjusting procedure

More than 70 (2.3, 2.5) Oil level is right.Pour in same amount of oilas was drained out.

Less than 70 (2.3, 2.5) Oil level is low.Pour in 70 (2.3, 2.5) of oil

2) If the oil contains chips or other foreign material flushwith the air conditioner system refrigerant and replacethe accumulator.Then add the oil.

Adding Oil for Replacement Component Parts

When replacing the system’s component parts, be sure to addthe following amount of oil to the parts being replaced.

Component parts Amount of oilto be replaced cc (US fl oz, Imp fl oz)

Evaporator coreCondenserAccumulator

90 (3.0, 3.3)30 (1.0, 1.1)30 (1.0, 1.1)

9 7 - 2 6


HOSE AND LINE CHECK

Check the heater and air conditioner hoses and lines for damagedue to interference with adjoining parts. If damage is major,replace the affected parts.Carefully check the hoses and lines, especially those locatedclose to moving parts or sharp panel edges.

CHECKING REFRIGERANT LEAKS

Conduct a leak test with an electronic leak detector wheneverleakage of refrigerant is suspected and when conducting serviceoperations which are accompanied by disassembly or looseningof connection fittings.

Electronic Leak Detector

The leak detector is a delicate device that detects small amountsof halogen. In order to use the device properly, read themanuals supplied by the manufacturer to perform thespecified maintenance and inspections.

If a gas leak is detected, proceed as follows:1.

2.

3.4.

Check the torque on the connection fitting and, if necessary,tighten to the proper torque, Check for leakage with the leakdetector.If leakage continues even after the fitting has beenretightened, discharge the refrigerant from the system,disconnect the fitting, and check the seat for damage.Replace fitting, even if the damage is slight.Check compressor oil and add oil if required.Charge the system and recheck for leaks. If no leaks arefound, evacuate and charge the system.

OFF-SEASON MAINTENANCE

In the off-season, turn the compressor on for 10 minutes at leastonce a month and run the engine at idle.Check the compressor belt for proper tension.

Belt deflectionDrive belt.. . . . . . . . . . . . . . . . . 9.0-10.4 mm (0.35-0.40 in.)A/C compressor belt.. . . . . . . . . . . . . . . . . . . . . . 8.0-10.0 mm


SPRING LOCK COUPLING

DISASSEMBLY

CAUTIONDischarge the system before disconnecting a coupling.

1. Install the special tool, 09977-33600 (A/B) on the coupling.2. Push the special tool into the cage opening to release the

female fitting from the garter spring.

3. Pull the male and female fittings apart.4. Remove the tool from the spring lock coupling.

ASSEMBLY

1. Check for a missing or damaged garter spring.Remove the damaged spring with a small hooked wire. Installa new spring if damaged or missing.

2. After cleaning the fittings, installing new O-rings. Lubricatedwith clean refrigerant oil, Assemble the fitting together bypushing with a slight twisting motion.

3. To ensure engagement, visually check that the garter springis over the flared end of the female fitting.

Male fitting Cage

Clean fitting

Garter spring

9 7 - 2 8


REFRIGERANT SYSTEM PERFORMANCEEVALUATION

The best way to diagnose a problem in the refrigerantsystem is to note the system pressures (shown by themanifold gauges) and the clutch cycle rate and times.Then, compare the findings with the charts (Figures 1and 2).

o The system pressures are low (compressor suction)and high (compressor discharge).

o Clutch cycle times are the lengths of time (inseconds) that the clutch is ON and OFF.

The following procedure is recommended for achievingaccurate diagnosis results in the least amount of time.1. Connect a manifold gauge set.

NOTE:The test conditions, specified at the top of eachchart, must be met to obtain accurate test results.

2. As soon as the system is stabilized, record the highand low-pressures as shown by the manifoldgauges.

3. Determine the clutch cycle time.4. Record clutch off time in seconds.5. Record clutch on time in seconds.

6. Record center register discharge temperature.7. Determine and record ambient temperatures.8. Compare test readings with the applicable chart.

(Figures 2 and 3)

o Plot a vertical line for recorded ambient temperaturefrom scale at bottom of each chart to top of eachchart.

o Plot a horizontal line for each of the other testreadings from scale at LH side of appropriate chart.

If the point where the two lines cross or each of thecharts falls within the band of acceptable limits, thesystem is operating normally. If the lines cross outsidethe band on one or more of the charts, there is aproblem and the specific cause must be determined.this is easily done by using the Refrigerant System andClutch Cycle Timing Evaluation chart (Figure 3).Refer to the following five system operating conditionsindicated by where the lines cross on the charts.

o System high (discharge) pressure is high, low, ornormal.

o System low (suction) pressure is high, low, ornormal.

o Clutch cycle rate is fast, slow, or the clutch runscontinuously.

IMPORTANT TEST REQUIREMENTSThe following test conditions must be established to obtainaccurate clutch cycle rate and cycle time readings.o Run engine at 1500 rpm for 10 minutes.o Operate A/C system on max A/C (recirculating air)o Run blower at max speed.o Stabilize in temperature 70°F to 80°F (21°C to 22°C)

NORMAL CENTER REGISTERDISCHARGE TEMPERATURES

AMBIENT TEMPERATURES AMBIENT TEMPERATURES

NORMAL FIXED ORIFICE TUBE CYCLING CLUTCHREFRIGERANT SYSTEM PRESSURES

Fig.1 Normal Fixed Orifice Tube Refrigerant System Pressure/Temperature Relationships

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IMPORTANT TEST REQUIREMENTSThe following test conditions must be established toobtain accurate clutch cycle rate and cycle time readings.o Run engine at 1500 rpm for 10 minutes.o Operate A/C system on max A/C (recirculating air)o Run blower at max speed.o Stabilize in temperature 70°F to 80°F (21°C to 22°C)

NORMAL CLUTCHSECONDS OFF TIME-SECONDS

AMBIENT TEMPERATURES

NORMAL CLUTCH CYCLE RATE MINUTE

CYCLES/MINUTE

NORMAL CLUTCHSECONDS ON TIME-SECONDS

AMBIENT TEMPERATURES

Fig. 2 Normal Fixed Orifice Tube Refrigerant System Clutch Cycling Timing Rates

o Clutch on time is long or short.o Clutch off time is long or short.Match these conditions to the conditions shown in thefive columns toward the left in the System Pressure andClutch Cycle Timing Evaluation chart (Figure 2). All fivesystem conditions will be indicated on one line. Themost likely component or components causing theproblem are listed in the column at the RH side of thechart.

Example:o High (discharge) pressure is low.o Low (suction) pressure is normal.o Clutch cycle rate is very fast.o Clutch on time is very short.o Clutch off time is very short.

The component causing the problem is the clutchcycling pressure switch. The cycling range is too close.Replace the switch and recheck the system.

Example:o High (discharge) pressure is normal to low.o Low (suction) pressure is normal.o Clutch cycle rate is fast.o Clutch on time is short.o Clutch off time is short.

The component causing the problem is the evaporatorcore. Airflow is restricted, indicating debris enteringthrough the cowl air inlet and plugging the core.The condition can also be detected by checking thecenter register discharge temperature. An abnormallylow temperature would mean air is spending more timein the evaporator and is very cold when discharged,although the volume is not enough to cool the vehicleproperly.At the bottom of the chart (Figure 3). additional causecomponents are listed for poor compressor operation ora damaged compressor condition.

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The two diagnosis charts which follow Figure 3 providethe most direct and sure way to determine the causeof any problem in a poorly performing refrigerantsystem. These charts are titled:o Insufficient or No A/C Cycling-Fixed Orifice Tube

Cycling Clutch System (Test Steps A1 through A11).o Compressor Clutch Circuit Diagnosis (Test Steps B1

through B11)

After servicing and correcting a refrigerant systemproblem, take additional pressure readings and observethe clutch cycle rate while meeting the conditionalrequirements (Figure 34) to ensure that the problem hasbeen corrected.In ambient temperatures above 38°C (100°F), thecompressor clutch will not normally cycle off and inmany instances, the clutch will not cycle off whentemperatures are above 32°C. (90°F) This will dependon local conditions and engine/vehicle speed. Also,clutch cycling will normally not occur when the engineis operating at curb idle speed. If the system containsno refrigerant or is extremely low in refrigerant, theclutch will not engage for compressor operation. A rapidcycling compressor clutch is usually and indication thatthe system is low on refrigerant. Refer to Insufficientor No A/C Cooling-Fixed Orifice Tube Cycling ClutchSystem Diagnosis chart.

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REFRIGERANT SYSTEM PRESSURE AND CLUTCH CYCLE TIMING EVALUATION CHART

NOTENormal system conditional requirements must be maintained to properly evaluate retrigerant system pressures.Refer to charts applicable to system being tested.

High(Discharge)

pressure

Low(suction)pressure

Clutch cycle timeComponent-Causes

Rate ON OFF

Condenser-Inadequate Airflow

Engine overheating

High

Normalto high

Normal

High

High

Normalto High

Continuous runAir in systemrefrigerant overcharge(a)Humidity or ambient temp very high(b)

Fixed orifice tube-Missing.O-rings Leaking/Missing

Normal High

Normal High Slow Long Long Clutch cycling switch-High Cut-in

Moisture in refrigerant system.Excessive refrigerant oil.

Slow or Long orno cycle continuous

Fast Short

Normal orno cycle

NormalNormal

ShortClutch cycling switch-Low Cut-in or High Cut-Out

Clutch cycling switch-Low cut-out

LongNormal

Normalto low

Low

High

Normalto high

Compessor-Low Performance

Continuous runA/C suction line-Partially Restrictedor Plugged(c)

Normalto low

Short Normal Evaporator-Low Airflow

Condenser, fixed orifice tube, or A/Cliquid line-Partially Restricted or Plugged

Short tovery short

Normal tolong

Normalto low

Normal FastLow refrigerant charge

Evaporator core-Partially Restricted or Plugged

A/C suction line-Partially Restricted orPlugged.(d).Clutch cycling switch-Sticking Closed

Normalto low

Continuous runLow

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High Low Clutch cycle time(Discharge) (Suction) Component-Causes

pressure pressure Rate ON OFF

Low Normal

Erratic operationor compressor notrunning

Veryfast

-

Veryshort

-

Veryshort

-

Clutch cycling switch-Cycling Range Too Close

Clutch cycling switch-Dirty Contacts or StickingOpen.Poor connection at A/C clutch connector orclutch cycling switch connector.A/C electrical circuit erratic-See A/C ElectricalCircuit Wiring Diagram

Additional possible causesassociated with inadequate compressor operation

o Compressor clutch slipping. o Loose drive belto Clutch coil open-Shorted or loose mountingo Control assembly switch-Dirty contacts or sticking openo Clutch wiring circuit-High resistance. Open or blown fuse

Additional possible causesassociated with a damaged compressor

o Clutch cycling switch-Sticking closed or compressor clutch seizedo Suction accumulator drier-Refrigerant oil bleed hole pluggedo Refrigerant leaks

1) Compressor may make noise on initial start-up. This condition can be caused by excessive liquid refrigerant.2) Compressor clutch may not cycle in ambient temperatures above 80°F depending on humidity.3) Low pressure reading will be normal, to high if the pressure readings are taken at the accumulator and if

the restriction is down stream of the service access valve.4) Low pressure reading will be low if pressure readings are taken near the compessor and the restriction is

upstream of the service access valve.

Fig.3 Refrigerant System Pressure and Clutch Cycle Timing Evaluation-Fixed Orifice Tube Cycling Clutch System.

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COMPRESSOR ASSEMBLY

COMPRESSOR

COMPONENTS


1. Remove the distributor assembly.2. Loosen the tension pulley and then remove the belt.3. Discharge the refrigerant.4. Disconnect the magnetic clutch connector,5. Remove the discharge hose and suction hose.6. Remove the compressor from the compressor bracket

assembly.7. Installation is the reverse of removal.

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COMPRESSOR ASSEMBLY

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

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COMPRESSOR ASSEMBLY

DISASSEMBLY

CLUTCH FRONT PLATE

Removal

1. Removal of U-NUT1) Temporarily install two M6 bolts, 25 mm (.98 in.) or

longer, in the bolt holes of the clutch front plate.

NOTE:Make sure the ends of the bolts do not contact thefront housing.

2) Use two box-end wrenches to hold the bolts (so as toprevent the clutch front plate from turning). Then removethe nut.

3) Remove the clutch front plate from the shaft.

2. Remove the clutch front plate using the clutch front platepuller (09977-21110).1) Align the puller center bolt on the compressor shaft.2) Hand tighten the three puller bolts into the thread holes.3) Turn the center bolt clockwise with the socket until the

clutch front plate is loosened.

3. Remove the clutch shims.4. Remove the bearing dust cover.

5 . Remove the external front housing snap ring using snap ringpliers.

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COMPRESSOR ASSEMBLY

6. Using the puller, remove the rotor pulley assembly.

7. Loosen the clutch lead wire from the clip on top of thecompressor front housing.

8. Using snap ring pliers, remove the snap ring and field coil.

INSTALLATION

1. The coil flange protrusion must match the hole in the fronthousing to prevent coil movement and to correctly positionthe lead wire.

2. Place the coil snap ring into position using pliers.

NOTEMake sure the snap ring is firmly in place.

3. Tighten the wire clip

Torque . . . . . . . . . . . . 20-25 Nm (200-250 kg.cm, 14-18)

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COMPRESSOR ASSEMBLY

4.

5 .

6.

7.

8.

9.

Install the pulley assembly using the special tool. (09977-21811).

NOTE1) Press in the rotor bearing outer race.2) After installation, rotate the pulley assembly and check

for proper installation.

Reinstall the external bearing snap ring with pliers.

NOTEWhen installing the snap ring, be careful not to scratch thesurface of the bearing with pliers.

Using the special tool (09977-21800) install the bearingdust cover,

NOTEAfter installation, rotate the clutch pulley. Check thatthere is no contact between the cover and front housing.

Reinstall the clutch spacer shims.

NOTECheck that the original clutch shims are in place on thecompressor shaft.

Align the front plate key-way to the compressor shaft key.Then install the front plate using a socket.

With the special tool, (09977-21110). tighten the U-Nut tospecifications.

Torque . . . . . . . . . . . . . . 17-19 Nm (170-190, 12-14 Ib.ft)

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COMPRESSOR ASSEMBLY

10. Check the air gap and clutch engagement.1) Place a dial gauge onto the clutch front plate.2) Apply 8V DC to the coil and check clutch engagment. The

air gap (readings before and after the engagement)should be as follows.Air gap between the front plate and clutch rotor: 0.4-0.8mm (0.016 - 0.032 in.)

3) If the air gap is out of specifications, remove the U-Nutand front plate.

4) Replace the shims with ones of different thickness toadjust the air gap.

SHAFT SEAL ASSEMBLY

Removal

1. Remove the shaft key by lightly tapping it with a screw driverand plastic hammer.

2. Using the snap ring pliers, insert the tool points into the twoholes of the felt ring metal retainer and lift out the felt ring.

3. Remove the shaft seal seat retaining snap ring with pliers.

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COMPRESSOR ASSEMBLY

4. Insert the seal seat remover (09977-21400) against theseal plate and twist the seal seat remover until it engagesthe plate and lift out.

5. Insert the shaft seal remover (09977-21500) against theseal assembly. Press down against the seal spring and twistthe tool until it engages the slots of the seal cage. Lift outthe seal assembly.

INSTALLATION

The shaft seal assembly should never be reused.Never re-use any parts of the assembly.Replace the complete assembly.Make sure all foreign substances are thoroughly removed fromthe compressor shaft and front housing.Do not touch the surface of the seal while handling the sealassembly.1. Insert the shaft seal guide (09977-21700) over the

compressor shaft. Apply refrigerant oil onto the outer surfaceof the shaft seal guide.

2. Clean the seal surface and O-ring with an air nozzle. Applyclean refrigerant oil to the seal surface.Place the slots of the shaft seal remover (09977-21510)into the new seal assembly. Firmly press and twist clockwise,until the seal assembly is engaged. Twist the tool in theopposite direction to disengage the tool from the seal cage.Remove the tool.

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COMPRESSOR ASSEMBLY

3. Coat the seal retainer with clean refrigerant oil.Use the tool to install. Press lightly against seal.

4. Remove the shaft seal guide.

5. Install the snap ring.

NOTEThe beveled edge faces outward from the compressor andthe flat side faces towards the compressor.

6. Check for refrigerant leakage.1 ) Install the shaft nut onto the compressor shaft and rotate

the compressor shaft several times using a socket.2) Charge the compressor and check for leakage at the

shaft seal using a leak detector.

7. Insert a new felt ring into the front housing and press evenlywith the special tool (09977-21400).

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COMPRESSOR ASSEMBLY

8. Using pliers, press the key into place. Be careful not todamage the compressor shaft when installing.

C Y L I N D E R H E A D A N D V A L V E P L A T E

REMOVAL

1. Remove the six cylinder head cap screws using a 13 mmsocket.

2. Use a small plastic hammer and a gasket scraper to tap theouter edge of the cylinder head until it is loose from the valveplate. (The cylinder head gasket normally sticks to the valveplate.)Do not scratch the cylinder head or valve plate whenremoving.

3. Position the gasket scraper between the outside edge of thevalve plate and the cylinder block and tightly tap the valveplate loose.

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COMPRESSOR ASSEMBLY

4. Using the gasket scraper, remove the cylinder and headgaskets.Do not damage the cylinder block or valve plate surfaces.

INSTALLATION

1. Coat the valve plate with refrigerant oil and install thecylinder block gasket.

2. Align the valve plate locating pins to the pin holes in theblock and position the valve plate.

3. Coat the valve plate with refrigerant oil and install thecylinder head gasket.

4. Align the valve plate locating pins to the pin holes in thecylinder head and position the cylinder head.Tighten the six bolts in the cylinder head with a torquewrench.

Torque . . . . . . . . . 34-36Nm (340-360 kg.cm, 25-26 Ib.ft)

COMPRESSOR ASSEMBLY

Rotor Pulley Bearing

Removal and Installation

1. Remove the bearing snap ring.

2. Using the special tools, (09977-21811 and 09216-21300)remove the bearing.

3. Using the special tool, (09977-21811) install the bearing.

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EVAPORATOR ASSEMBLY

EVAPORATOR

COMPONENTS


1. Discharge the refrigerant from the lines system.2. Disconnect the suction and liquid lines.3. Remove the grommet cover.4. Remove the console assembly.5. Remove the glove box assembly.

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EVAPORATOR ASSEMBLY

6. Remove the main lower crash pad, lower crash pad centerfacia panel and lower crash pad center skin.

7. Remove the blower assembly.8. Remove the evaporator assembly.9. Installation is the reverse of removal.

INSPECTION

1. Check for damage to the evaporator fins.2. Check for a damaged or collapsed drain hose.3. Check for peeling or cracking of the insulation.

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CONDENSER ASSEMBLY

CONDENSER

COMPONENTS

ON-VEHICLE INSPECTION

1. Check the condenser fins for restriction or damage.If the fins are restricted, wash them with water and dry withcompressed air. If the fins are bent, straighten with ascrewdriver or fin straightener.

CAUTIONBe careful not to damage the fins.

2. Check the condenser fittings for leakage.

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CONDENSER ASSEMBLY

REMOVAL

1. Lift the hood.2. Discharge the refrigerant from the system.3. Disconnect the discharge line from the condenser inlet fitting

using the special tool. (09977-33600)4. Remove the radiator grille.5. Remove the radiator assembly.6. Disconnect the liquid line from the condenser outlet fitting.

INSTALLATION

1. Installation is reverse of removal.2. If the condenser is replaced, add refrigerant oil to the

compressor (1.8 US fl oz, 1.9 Imp fl oz)3. Evacuate, charge and test refrigeration system.

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CONDENSER FAN & RELAY

CONDENSER FAN ASSEMBLY

ON-VEHICLE INSPECTION

1. Check the condenser fan for restrictions or damage.2. Check the harness connection.


1. Disconnect the battery ground cable.2. Disconnect the connector from the A/C harness.3. Remove the fan assembly.4. Installation is the reverse of removal.

INSPECTION

1. Using an ohmmeter, check that there is continuity betweenterminals L and B.

RELAY

INSPECTION

1. Using an ohmmeter, check to be sure that there is nocontinuity between terminals L and B.

2. Apply 12 volts across Terminals S1 and S2 then checkcontinuity between terminals L and B.Replace if necessary.

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BLOWER ASSEMBLY

B L O W E R A S S E M B L Y

COMPONENTS


1. Remove the glove box housing cover assembly.2. Remove the lower crash pad assembly.3. Disconnect the resistor and blower motor connector.4. Pull out the blower unit and then disconnect the fresh/recirc

vacuum connector.5. Installation is the reverse of removal.

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BLOWER ASSEMBLY

INSPECTION

1. Check for bending or abnormal deflection of the rotatingshaft of the blower motor assembly.

2. Check for cracking or deterioration of the packing.3. Check for damage to the fan.4. Check for damage to the blower case.5. Check the operation of the inside/outside air selection

damper, and for damage.6. Connect the blower motor terminals directly to the battery

and check that the blower motor operates smoothly.7. Next, reverse the polarity and check that the blower motor

operates smoothly in the reverse direction.

8. Using an ohmmeter, check that there is continuity betweenterminals 1 and 2.If there is no continuity, replace the resistor.

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ACCUMULATOR ASSEMBLY

ACCUMULATOR

COMPONENTS

REPLACEMENT

It will be necessary to replace the accumulator for the followingreasons.1. The accumulator is restricted, plugged or damaged.2. The system has been left open for more than 24 hours.

(system completely discharged)3. There is evidence of moisture in the system.4. A component such as a condenser, evaporator core,

refrigerant line or a seized compressor is replaced.

NOTE:It is not necessary to replace the accumulator when thereis a partial loss of refrigerant charge or a dent is foundin the outer shell of the accumulator.

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ACCUMULATOR ASSEMBLY

REMOVAL

1. Discharge the air conditioning system.2. Disconnect the two suction line from the accumulator.3. Disconnect the wiring harness.4. Remove the accumulator from the bracket.5. Remove the clutch cycling switch.

NOTEPlug all open fittings immediately to keep moisture out ofthe system.

INSTALLATION

1. Install the accumulator in the bracket.

NOTEDo not remove the plugs until ready for connection.

2.3.

4.5.6.7.

Connect the liquid lines to the accumulator.If the accumulator is replaced with a new unit, add 30cc ofcompressor oil to the accumulator.Install the clutch cycling switch.Connect the wiring harness.Charge the system.Check for any refrigerant leaks.

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Hyundai Excel X2 1989-1998 Air Conditioning

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Transcript of Hyundai Excel X2 1989-1998 Air Conditioning