AIR CONDITIONING SYSTEM

6810-00/6810-01/6810-02/6810-03/6810-05/
6810-06/6810-11/6810-12/6810-15/6810-20/
6810-24/6820-01/6830-01

AIR CONDITIONING SYSTEM

GENERAL INFORMATION REMOVAL AND INSTALLATION

1. SPECIFICATION.................................... 3 6810-20 FATC SELF DIAGNOSIS.............. 40

6810-20 HEATER AND A/C CONTROL
ASSEMBLY.................................. 44
OVERVIEW AND OPERATING 6810-01 A/C MODULE............................... 50
6810-12 MODE ACTUATOR ASSEMBLY.. 56
PROCESS
6810-02 TEMPERATURE ACTUATOR
1. SYSTEM LAYOUT................................. 4 ASSEMBLY.................................. 58
2. HEATER AND A/C CONTROL................ 6 6810-11 INTAKE ACTUATOR ASSEMBLY 60
3. A/C COOLING CYCLE............................ 10 6810-11 WATER TEMPERATURE
4. A/C COOLING CIRCUIT.......................... 12 SENSOR...................................... 62
5. A/C CIRCUIT DIAGRAM......................... 13 6810-24 INTAKE SENSOR......................... 64
6810-06 MOS MODULE............................. 66
6810-05 BLOWER MOTOR ASSEMBLY ... 68
COMPONENT
6810-03 AIR FILTER ASSEMBLY.............. 70
6810-03 PTC HEATER............................... 72
6810-01 AIR CONDITIONER MODULE....... 14
6820-01 AIR CONDITIONER HOSE &
PIPE............................................. 15
6830-01 AIR DISTRIBUTOR....................... 16
6810-20 HEATER AND A/C CONTROL
ASSEMBLY.................................. 17
6810-00 A/C MODULE............................... 24
6810-15 PTC HEATER ASSEMBLY........... 38
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AIR CONDITIONING SYSTEM

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AIR CONDITIONING SYSTEM 6810-20

GENERAL INFORMATION
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
Capacity (kcal/h) 4,700
Blower Supplied power (W) 240 + 10% Max (at 12V)
Fan speed (rpm) 2900 ± 200 Max
(Rec.Mode: 420㎥/h)
PTC Supplied power 1 kW
Condenser Core size (㎣) 588 x 455 x 16 (2,625)
Capacity (kcal/h) 12,000
Capacity of receiver drier 250 cc
Compressor Capacity 170 cc/rev
Diameter of pulley Ø120
Max. speed 8,000 rpm
Voltage DC 12 V
Current consumption 2.2A

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OVERVIEW AND OPERATING PROCESS

1. SYSTEM LAYOUT
Line & port

Low pressure hose

High pressure hose

Electric fan

A/C condenser & receiver dryer A/C compressor

Integrated
receiver
dryer

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FATC In-car sensor

Sun-load sensor

Refrigerant pressure

sensor

Engine ECU
Ambient air temperature
sensor

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2. HEATER AND A/C CONTROL

1) Full Automatic Air Conditioner

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.
Recirculation switch
- LO: Low temperature,
- HI: High temperature When you press this switch,
recirculation indicator comes on
and the system is changed into
the recirculation mode.
When you press the switch
again, recirculation indicator
goes out and the system is
changed into the fresh air mode.

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▶ Mode dial

Select the desired airflow mode by turning this dial.

Face/Foot -Level Foot-Level

(bi-level mode) (foot mode)

Foot/Defrost-Level
(foot/defrost mode)

Face-Level
(vent mode) Defrost mode
When choosing this mode, the
Airflow is changed
airflow direction will be changed
automatically according to
to the windshield and side
the setting temperature.
glasses, the air conditioner
In-car sensor operates automatically, and
fresh air comes in.
This sensor detects the inside temperature
and installed in PCB.

▶ Fan speed dial

Fan speed dial

- Manual control
Fan speed is manually
controlled by this dial. The
increment is 1℃.
A/C switch
- Auto control
When you press this
Fan speed is automatically
switch, the indicator comes
controlled by temperature
on and the air conditioner
setting.
starts to operate.

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2) Manual A/C Control

Fan speed dial Mode dial Temperature dial

A/C switch Recirculation switch

▶ Fan speed dial

Fan speed dial

To adjust the fan speed, turn
this dial as required.
- OFF: Fan does not operate.
A/C switch Fan speed level consists of 7
When you press this switch, the steps.
indicator comes on and the air
conditioner starts to operate.
When you press the switch
again, the air conditioner stops
operation and the indicator
goes out.

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▶ Mode dial

Foot-Level (foot mode)

Face/Foot-Level
(bi-level mode)

Foot/Defrost-Level
(Foot & defrost mode)
Face-Level (vent mode)

Defrost mode
When choosing this mode, the airflow
direction will be changed to the
windshield and side glasses, the air
conditioner operates automatically,
and fresh air comes in.

▶ Temperature dial

Temperature dial
To adjust the temperature,
turn this dial as required.
Recirculation switch - Blue: Low temperature,
When you press this switch, - Red: High temperature
recirculation indicator comes on
and the system is changed into the
recirculation mode.
When you press the switch again,
recirculation indicator goes out and
the system is changed into the
fresh air mode.

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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 liquefied it in high
pressure.
(3) Receiver Dryer
- Condition: Gas/Liquid
- Function: Keeps the refrigerant dried 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.

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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 regulate the amount of the refrigerant exactly.
(4) Evaporation

- 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.

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4. A/C COOLING CIRCUIT

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5. A/C CIRCUIT DIAGRAM

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COMPONENT
6810-01 AIR CONDITIONER MODULE

1. Blower assy 12.Actuator assy - Mode

2. Actuator assy - Intake 13.Core assy - Heater
3. Air filter assy 14.Core - Evaporator
4. Cover - Air filter 15.Heater assy - PTC
5. Blower motor assy 20.Control assy - Heater & A/CON
6. Resistor 21.Screw
7. Expansion valve assy 22.Insert assy - ventilation
9. Wiring assy - Heater & evaporator 23.Sensor - Incar
10.Heater & evaporator assy 24.Sensor - Intake
11.Actuator assy - Temp

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6820-01 AIR CONDITIONER HOSE& PIPE

1. Condenser assy 12.Pipe assy - Liquid & suction

2. Compressor assy - A/con 13.Nut
3. Hose assy - Discharge & suction 14.Oil ring - Suction
4. Nut 15.Oil ring - Liquid
5. Oil ring - Suction 16.Oil ring - Suction
6. Oil ring - Discharge 17.Oil ring
7. Oil ring 18.Hose - Drain
9. Hose assy - Heater inlet 22.Brkt assy - A/con comp
10.Hose assy - Heater outlet 23.Bolt
11.Clamp 24.Bolt

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6830-01 AIR DISTRIBUTOR

1. Duct - Foot
2. Duct - Foot
3. Duct assy - RR heating No1
4. Duct assy - RR heating No1
5. Duct assy - Rr heating No2
6. Nut

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6810-20 HEATER AND A/C CONTROL ASSEMBLY

Recirculation Switch Dial Indicator

Temperature Dial Switch Indicator

Mode Dial In-car Sensor

Fan speed Dial

A/C Switch

The FATC (Full Automatic Temperature Control) is a temperature control device which receives
signals from various sensors (incar 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 temperature of the vehicle interior 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.

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1) Input/Output Diagram

▶ A/C compressor control by engine ECU

1. Coolant temperature: 20℃ or less
2. Coolant temperature: 115℃ or more
3. For approx. 4 seconds after starting the engine
4. When the engine speed is below 650 rpm
5. When the engine speed is over 4,500 rpm
6. During abrupt acceleration for the vehicle equipped with manual transmission

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2) Major Features
(1) Temperature control
In AUTO mode, the FATC receives various input
values, 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.

(2) Blower motor (fan) speed 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
The motor is manually controlled by turning
the blower dial. Turning the dial clockwise or
counterclockwise changes the fan speed by 1
step.

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
The fan speed is controlled automatically according to the set temperature and the ambient
conditions.
▶ 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.

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▶ 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. And then the mode is changed to VENT mode or BI-LEVEL
mode to prevent the hot air from suddenly discharging to the front passengers.

▶ 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) Fresh Air/Recirculation Control

▶ Manual control
The air source door can be controlled manually by pressing the recirculation switch.
The air source mode is switched between the fresh air and recirculation alternatively
each time the switch is pressed.

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▶ 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:

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 dial clockwise or
counterclockwise.
The dial indicator for the selected mode
comes on to inform the operator.

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▶ 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

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 Blower Air source

temperature compressor mode source voltage door
LO ON Vent Recirculat 10.5 (V) Max. cooling
ion 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 less) for protection against damage.

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6) FATC Terminals
(1) Controller connector terminals

A1 A10 B1 B6

A11 A23 B7 B12

(2) Description of terminals

Pin No. Function Pin No. Function

A1 P2 (Intake) A19 PBR (Mix)
A2 P2 (Mode) A20 PBR (Intake)
A3 P2 (Mix) A21 Blower operating signal
A4 P1 (Mix) A22 FATC illumination light (+)
A5 P1 (Mode) A23 FATC illumination light (-)
A6 Vehicle speed signal B1 -
A7 REF B2 -
A8 PTC heater assembly B3 -
A9 IGN ON power B4 Water temperature sensor signal
A10 Battery power B5 Incar sensor signal
A11 P1 (Intake) B6 -
A12 Compressor operating signal B7 -
A13 Intake sensor signal B8 -
A14 Blower feedback signal B9 -
A15 Blower motor control signal B10 Sun-load sensor signal
A16 Sensor ground B11 Ambient temperature sensor signal
A17 Ground (Power) B12 -
A18 PBR (Mode)

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6810-00 A/C MODULE

1) Sensors & Actuators

Mode actuator Temperature actuator

Water temperature sensor Intake sensor

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Air filter Intake actuator

PTC heater Blower motor

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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
Mode actuator assembly
a. Turn the ignition ON. Then, check the operation position of the actuator each time the
mode is changed.
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.

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▶ Mode door actuator operation position

Bi-level

Foot
Vent

Defrost/Foot

Defrost

▶ Mode door actuator connector

Pin No. Function

1 -
2 REF
3 PBR
4 Sensor ground
5 P2
6 P1

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(2) Intake Actuator Assembly

Intake actuator

▶ Function
Intake actuator assembly
Controls the air source door (intake) by the FATC command.

▶ Maintenance
Intake actuator assembly
a. Turn the ignition ON. Then, check the operation position of the actuator each time the air
flow mode is changed.
b. If the operating position is not correct, check the wiring for open circuit.
c. If the wiring is intact, replace the intake actuator assembly.

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▶ Intake actuator operation position

Recirculation

Fresh air

▶ Intake actuator connector

Pin No. Function

1 -
2 REF
3 PBR
4 Sensor ground
5 P2
6 P1

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(3) Temperature Actuator Assembly

Temperature actuator

▶ Function
Temperature actuator assembly
Adjusts the temperature of the indoor air by controlling the temperature actuator assembly
position according to the FATC command.

▶ Maintenance
Temperature actuator assembly
a. Turn the ignition ON. Then, check the operation position of the actuator each time the air
flow mode is changed.
b. If the operating position is not correct, check the wiring for open circuit.
c. If the wiring is intact, replace the temperature actuator assembly.

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▶ Temperature actuator operation position

Cooling

Heating

▶ Temperature actuator connector

Pin No. Function

1 -
2 REF
3 PBR
4 Sensor ground
5 P2
6 P1

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(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 and detects the
temperature of the interior air coming from senor hole. And the sensor sends the voltage
value according to the resistance change 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
connector.
(Specified value: 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. (Specified value: 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.

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(5) Water Temperature Sensor

Water temperature sensor

▶ Mounting location
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 connector.
(Specified value: 2.186 ㏀ ± 3% at 25℃)
If the measured resistance is extremely high or low, replace the water temperature sensor.
b. If the measured value is out of the specified range, replace the water temperature 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.
15 and 11 of the FATC connector. (Specified value: approx. 1.1 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.

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(6) Intake Sensor

Intake sensor

▶ Mounting location
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
connector.
(Specified value: 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:
- Turn the ignition switch to ON position and measure the voltage between the pin no.
21 and 18 of the FATC connector. (Specified value: approx. 5.1 V at 1℃)
- 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.

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(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 (Fault code 6), check as described below:
- Turn the ignition switch to ON position.
- Measure the voltage between the two 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:

Item 1 2 3 4 5 6 7
Voltage FATC 4V 5V 6.5 V 8.5 V 10.5 V 11 V to -
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.

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(8) Ambient Temperature Sensor

Ambient temperature sensor

▶ Mounting location
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 FATC.

▶ 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.
(Specified value: 2.186 ㏀ ± 3% at 25℃)
If the measured resistance is extremely high or low, replace the ambient temperature
sensor.
b. If the measured value is out of the specified range, replace the ambient temperature
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.
31 and 18 of the FATC connector. (Specified value: 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.

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(9) Sun-load Sensor

Sun-load sensor

▶ Mounting location
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 two terminals in direct
sunlight.
b. Measure the current again under shade. It is in normal if the measured value is less than
the measured value in direct sunlight.
- Turn the ignition switch to ON position and measure the voltage between the pin no.
32 and 18 of the FATC connector.
(Specified value: approx. 1.7 V in direct sunlight, approx. 3.1 V under shade)
- 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.

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6810-15 PTC HEATER ASSEMBLY

PTC heater

This device is mounted to the heater air outlet and increases the temperature of the air to the
passenger room.
Because the PTC system is heated by 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 does not operate when a) the
engine is cranking, b) the battery voltage is below 11 V, c) the glow plug is preheated.

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▶ PTC Operating (ON) Condition

Component PTC heater

Heating type Air heating type
Heating efficiency Excellent

Element Ceramic PTC (BaTio2)

Weight Excellent
Durability Approx. 500 g
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 the coolant temperature is less than 15℃
- When the coolant temperature is 15℃ or higher, the conditions for the 2nd step
described below must be satisfied.

2. 2nd step (Coolant temperature: 15℃)

- When the coolant temperature is 65℃ or less and the intake air temperature is -
10℃ or less
- When the coolant temperature is between 65℃ and 60℃ and the intake air
temperature is between -10℃ and 0℃
- When the coolant temperature is 60℃ or less and the intake air temperature is
between 0℃ and 5℃

▶ PTC "OFF" Condition

- A/C blower switch OFF

- Ambient temperature sensor malfunction (short or open circuit in the wiring)
- When the engine is cranking
- When the battery voltage is 11 V or less
- the glow plug is preheated (Glow indicator ON)

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01-40 6810-20

REMOVAL AND INSTALLATION

6810-20 FATC SELF DIAGNOSIS
(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 fault code by using the self diagnosis
function.

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

Recirculation switch
indicator comes on

A/C switch indicator

comes on

(3) How to Start Self Diagnosis

Turn the ignition switch to ON 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.

Recirculation 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

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(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.

Recirculation switch
indicator flashes:
Normal

A/C switch indicator

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

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▶ 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

A/C switch
indicator
comes on:
Malfunctioning

A/C switch
indicator
flashes: Normal Turn the mode dial to vent, bi-level,
foot, defrost/foot, defrost, in
sequence.
Turn the blower
dial to AUTO
position.

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▶ 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 then the actuator is normal.

Mode Diagnosed component Indicator for result

Vent Mode
Bi-level Temperature Recirculation switch indicator

Foot Intake

Recirculation switch
indicator
comes on:
Malfunctioning

Recirculation switch
Turn the mode dial to vent, bi-
indicator
level, foot, in sequence.
flashes: Normal

* For the 2nd and 3rd steps, 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.

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01-44 6810-20

6810-20 HEATER AND A/C CONTROL ASSEMBLY

1. Disconnect the negative cable from the battery.

Heater and A/C control

1. Remove the passenger side fascia panel.

1

2. Open the glove box and unscrew the two

2
mounting screws to remove the side
fascia molding.

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3. Unscrew the 5 side fascia panel

3
assembly mounting screws to remove the
side fascia panel.

4. Remove the side fascia panel assembly.

4

5. Unscrew the two cluster fascia panel

5
assembly mounting screws.

6. Lift out the cluster fascia panel assembly.

6

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7. Remove the center fascia molding

7
assembly.

8. Unscrew the center fascia panel

8
assembly mounting screw (A).

9. Remove the center fascia panel

9
assembly.

10.Unscrew the 4 audio mounting screws (A).

10

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11.Lift up the audio and disconnect the

11
connectors.
Wiring connector
USB connector
AUX connector
Antenna

12.Disconnect the switch module connector

12
under the audio.

13.Unscrew the 4 mounting screws (A)

13
for the heater and A/C control.

14.Remove the heater and A/C control

14
assembly.

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15.Disconnect the heater and A/C control

15
assembly connectors (A and B).

16.Disconnect the connectors under the

16
heater and A/C control assembly.

AUX connector
USB connector
Cigarette lighter connector

17.Remove the heater and A/C control

17
assembly.

18.Unscrew the 4 mounting screws located

18
behind the heater and A/C control
assembly.

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19.Install in the reverse order of removal.

19

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01-50 6810-01

6810-01 A/C MODULE

- Disconnect the negative cable from the battery and remove the instrument
panel assembly.
- Drain the A/C 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

1. Disconnect the heater hoses (inner/outer).

1

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2. Remove the cowl and unscrew the 3

2
wiper motor assembly mounting bolts (10
mm) to remove it.

3. Unscrew the two mounting bolts (10 mm).

3

4. Lift the vehicle with a lift and unscrew the

4
two mounting nuts securing the insulator to
the engine compartment.

5. Unscrew the A/C joint pipe mounting nut

5
(10 mm).

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01-52 6810-01

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 mounting 4 Cross member mounting Passenger side

bolts (12 mm) bolts 4 mounting bolts
(A, 12 mm) (12 mm)
Mounting screw (B)

Duct mounting screw (A) 2 Ground mounting bolt Duct mounting screw (A)/2
Mounting bolts (10 mm) mounting bolts (B, 12 mm).
(B, 12 mm)
Ground mounting bolt (C)
(10 mm)

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8. Disconnect the connectors of the body

8
main wiring connector assemblies on both
sides with the same method.

9. Disconnect the wiring connector.

9

10.Remove the mountings securing the wirings.

10

11.Remove the passenger side mountings

11
securing the wirings.

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01-54 6810-01

12.Remove the instrument frame.

12

13.Disconnect the PTC heater assembly

13
connector.

14.Disconnect the hose connected to the A/C

14
module.

15.Remove the A/C module.

15

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16.Install in the reverse order of removal.

16

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01-56 6810-12

6810-12 MODE ACTUATOR ASSEMBLY

1. Disconnect the negative cable from the battery.
2. Remove the lower main panel assembly.

Mode actuator

1. Disconnect the mode actuator connector.

1

2. Unscrew the two mounting screws for the

2
mode actuator.

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3. Remove the mode actuator.

3

4. Install in the reverse order of removal.

4

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01-58 6810-02

6810-02 TEMPERATURE ACTUATOR ASSEMBLY

1. Disconnect the negative cable from the battery.
2. Remove the lower main panel assembly.

Temperature actuator

1. Disconnect the temperature actuator

1
connector.

2. Unscrew the two mounting screws for

2
the temperature actuator.

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3. Remove the temperature actuator assembly.

3

4. Install in the reverse order of removal.

4

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01-60 6810-11

6810-11 INTAKE ACTUATOR ASSEMBLY

1. Disconnect the negative cable from the battery.
2. Remove the instrument panel.

Intake actuator

1. Disconnect the intake actuator connector.

1

2. Unscrew the two mounting screws for the

2
intake actuator.

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3. Remove the intake actuator assembly.

3

4. Install in the reverse order of removal.

4

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01-62 6810-11

6810-11 WATER TEMPERATURE SENSOR

1. Disconnect the negative cable from the battery.
2. Remove the lower main panel assembly.

Water temperature sensor

1. Disconnect the water temperature sensor

1
connector.

2. Unscrew the mounting screw.

2

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3. Remove the water temperature sensor.

3

4. Install in the reverse order of removal.

4

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01-64 6810-24

6810-24 INTAKE SENSOR

1. Disconnect the negative cable from the battery.
2. Remove the instrument panel.
3. Remove the A/C module.

Intake sensor

1. Disconnect the intake sensor connector.

1

2. Disconnect the mode actuator connector,

2
intake actuator connector and sensor
wiring from the A/C module, and remove
the blower assembly and the heater &
evaporator assembly.

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3. Separate the upper and lower parts of

3
the heater and evaporator assembly.

4. Remove the mountings on the heater and

4
evaporator assembly.

5. Remove the intake sensor located on the

5
evaporator core.

6. Install in the reverse order of removal.

6

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01-66 6810-06

6810-06 MOS MODULE

1. Disconnect the negative cable from the battery.
2. Remove the glove box housing.

MOS module

1. Remove the MOS module connector.

1

2. Unscrew the two mounting screws.

2

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3. Remove the MOS module.

3

4. Install in the reverse order of removal.

4

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01-68 6810-05

6810-05 BLOWER MOTOR ASSEMBLY

1. Disconnect the negative cable from the battery.
2. Remove the instrument panel.

Blower motor

1. Disconnect the blower motor connector.

1

2. Unscrew the 3 mounting screws.

2

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3. Remove the blower motor.

3

4. Install in the reverse order of removal.

4

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6810-03 AIR FILTER ASSEMBLY

Air filter assembly

1. Open the glove box, remove the locking

1
devices in sequence and lower them down.

2. Press the air filter cover mounting holder

2
to remove the cover.

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3. Remove the air filter.

3

4. Install in the reverse order of removal.

4

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6810-03 PTC HEATER

1. Disconnect the negative cable from the battery.
2. Remove the lower main panel assembly.

PTC heater

1. Disconnect the PTC heater connector.

1

2. Unscrew the two mounting screws for the

2
PTC heater.

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3. Remove the PTC.

3

4. Install in the reverse order of removal.

4

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