Air Conditioning (DATC) General course information Target group: KIA certified technicians Target of the course: To understand the components and location for AC system To understand system feature and logic To know how to maintenance of air conditioning system in XM. Mandatory pre- courses: Air Conditioning (Step 2) To understand the air conditioning system features in XM. Material: Training vehicle (XM) Training Part (HVAC) Hi-scan Pro / GDS Instructors guide Trainees textbook / File Practice sheets (Practice preparation) Workshop manuals Certificates Nameplates (Paper for notes) (Pens etc.) Method: Lecture Practice Task Lead over: Lets start with the general specification of the air conditioning system in XM. Air Conditioning (DATC) Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation. Technical Writing : Mr. Eric Song, March ‘09

General Specification The air conditioning system for XM has two variants, those are manual and auto (DATC). Recent DTAC system has no humidity and AQS also it is possible to communicate with the scanner. As for the actuators, temperature, mode and intake door actuator have been applied so that it contains the position sensor in order to implement feed back control as same as existing models. Additionally engine coolant sensor which was installed inside HVAC is eliminated, instead of that sensor DATC use engine coolant temperature signal through ECT. Finally rear HVAC for cooling is applied. To understand the air conditioning system features in XM. To understand changed components Material: Trainees textbook Training Vehicle (XM) Method: Lecture Question Lead over: Let’s have a look at the system layout. General Specification Item Description Remarks Compressor Variable Swash Plate Type Condenser Integrated with receiver drier Refrigerant pressure detection APT type Refrigerant quantity 500g HVAC type Semi-center mounting type Rear HVAC applied (cooling only) Cooling Fan Diesel : Single fan, Gasoline : 2 fan Cooling fan control Relay (Low / High) Evaporator sensor Fin thermo sensor type (inside evaporator core) Ambient temp. sensor Applied Humidity, AQS sensor Not applied Photo sensor 2 EA photo sensor - Driver : autolight - Passenger: airconditioning Engine coolant temp. sensor Shared with ETCon engine Actuator Temp., Mode, Intake Position sensor applied Blower speed FATC (8 steps), Manual (4 steps) Diagnosis Diagnosis tool & panel

HVAC Components HVAC Components Evaporator core MODE actuator Material: Trainees textbook Training part (HVAC) Method: Lecture Question Lead over: Lets have a look at the HVAC structure. MODE Actuator The mode control actuator is located at the HVAC unit. It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in order of vent → B/L → floor → mix. TEMP Actuator HVAC unit includes mode control actuator and temperature control actuator. Temperature control actuator is located at the HVAC unit. It regulates the temperature by the procedure as follows. Signal from control unit adjusts position of temperature door by operating temperature switch and then temperature will be regulated by the hot/cold air ratio decided by position of temperature door. All actuators have position senor so that control module knows each actuator’s position using feedback signal. . To understand the HVAC structure in XM. HVAC Components Evaporator core MODE actuator Fin thermo sensor TEMP actuator (Driver) TEMP actuator (Passenger)-DATC PTC heater (Diesel ONLY) Heater core

HVAC Components (HVAC) Climate Control Air Filter This has particle filter which eliminates foreign materials and odor. The particle filter includes odor filter as well as conventional dust filter to ensure comfortable interior environment. Intake Actuator -The intake actuator is located at the blower unit. - It regulates the intake door by signal from control unit. Pressing the intake selection switch will shift between recirculation and fresh air modes. Cluster ionizer It is possible to purify indoor air using ion generator. It is applied on DATC. Manual does not have cluster ionizer. FET The blower motor speed can be controlled 8 steps by FET for DATC and 4 steps by register for manual respectively. Material: Trainees textbook Training part (HVAC) Method: Lecture Question Task Lead over: Lets have a look at the rear A/C unit structure. To understand the HVAC structure in XM. HVAC Components (HVAC) Air filter cover Cluster ionizer Blower motor Intake actuator + ion generator - Ion generator FET (manual : register applied)

Rear A/C unit Rear A/C Unit Rear blower switch Evaporator core The rear A/C unit is consist of several units. Those are evaporator core, blower motor and register to control blower motor speed. Rear control switch is applied which can control rear A/C on & off and 3 steps (blower speed). Material: Trainees textbook Training part (rear A/C unit) Method: Lecture Question Lead over: Lets have a look at inputs & outputs element. To understand the rear A/C unit in XM. To understand the rear controller switch function Rear A/C unit Rear blower switch Evaporator core Blower fan & motor Register

Inputs & Outputs Inputs & Outputs Tail lamp, Rheostat IPM Fin thermo sensor It is inserted on the HVAC and detects the temperature of evaporator core in order to control the cooling and avoid the evaporator to be frozen. The negative thermal coefficient type sensor is applied so that the output voltage from the sensor is in inverse proportional to the temperature. Failsafe of fin thermo sensor If the fin thermo sensor is open or shorted circuit, the temperature will be alternated by -2℃. Photo sensor – Dual type -The photo sensor is located at crush pad -The photo sensor of XM is applied to dual type. Failsafe of photo sensor If the photo sensor is open or shorted circuit, it will be fixed with zero W/m2 (no sun light). In-car sensor In car sensor senses the temperature of cabin in order to control the target temperature which is set by the driver. In XM, the DC motor was applied to intake the cabin air instead of the aspirator type hose . Failsafe of In-car sensor If the In-car sensor is open or shorted circuit, the temperature will be alternated by 23℃. Ambient temperature sensor It is located at the front of radiator and detects the temperature of outside air. Failsafe of ambient temperature sensor If the ambient temperature sensor is open or shorted circuit, the temperature will be alternated by 20℃. Engine coolant sensor Engine coolant temperature sensor is located at the engine and it is used to control the blower speed and temperature. As same as other temperature sensors, the negative thermister type so that the output voltage from the sensor will drop as the coolant temperature increases. Failsafe of engine coolant temperature sensor If the engine coolant temperature sensor is open or shorted circuit, the temperature will be alternated by 85℃. APT It continuously senses the refrigerant pressure and inputs to the engine ECM in order to control the compressor and cooling fan for optimum cooling performance. - It substitutes the conventional triple switch. - It contributes to the lower fuel consumption and smooth shift feeling. - APT outputs the voltage and it inputs to engine ECM. To understand the inputs & outputs elements of A/C system applied in XM. Material: Trainees textbook Method: Lecture Question Lead over: Lets have a look at the cluster ionizer functions. Inputs & Outputs Tail lamp, Rheostat DATC module IPM Ambient temp. sensor. Engine coolant temp. sensor Fin thermo sensor In-car sensor Vehicle speed Dual photo sensor Rear defogger Hazard lamp switch Actuators (Mode, Temp., Intake) Eng. ECM APT A/C S/W (High) A/C load (High) Max. Hi blower Blower motor rear control Compressor, Condenser fan Blower ON signal PTC #1 ON signal Switches Auto, OFF, A/C, Recirculation, Fresh, Defroster, Defogger, Mode, Blower speed, Hazard lamp S/W etc. PTC #2 relay PTC #2 relay PTC #3 relay Dial switch (temperature, driver&pass) K-line (Diagnosis) Power (B+, IG2) and Ground

Cluster ionizer Cluster Ionizer + ion generator - Ion generator To understand the cluster ionizer main functions To understand operation logic To understand operating condition Material: Trainees textbook Training part (cluster ionizer) Method: Lecture Question Lead over: Lets have a look at the cluster ionizer functions. 1) Cluster ion: Ion formed by the combination of two or more identical ions or molecules in association with another atom, molecule, or ion. 2) Cluster ionizer : cluster ionizer is a relatively new device that is intended to purify the air. As its name implies, instead of using fans and filters, an air ionizer creates ions which remove microscopic particles from the air. Rooms are healthier for those suffering from asthma, allergies, impaired immunity, or respiratory ailments, without as many allergens circulating in the lungs. Cluster ionizers rely on the chemical properties of particles. An ion is just a particle that is charged, either negatively or positively. The ions flood and seek out positively charged particles, such as dust, dander, bacteria, pollen, mold, smoke, chemical vapors, and many other allergens. 3) Cluster ionizer advantage : Noiseless No secondary contamination Generate ion (ozone volume : less 0.02 ppm after 24 Hr operation) 4) Control logic: ① Operating condition - Ignition ON and - Blower motor working (over 1step) ② Stop condition - Ignition OFF or - Blower motor OFF - Cluster unit fault ③ Operation process - Ignition ON  CLEAN mode (13min)  ION mode (17min)  CLEAN mode (13min) :repeat - CLEAN mode start while blower motor OFF and air conditioning system ON regardless of former operating mode or operating time. - ION and CLEAN mode are stopped when stop condition is met. Cluster ionizer + ion generator - Ion generator Cluster ionizer Case PCB, IC High voltage generator

Cluster ionizer operating lamp To understand the cluster ionizer main functions To understand operation logic To understand operating condition Material: Trainees textbook Training part (cluster ionizer) Method: Lecture Question Lead over: Lets have a look at the rear blower control. ④ Circuit DATC sends operating signal to cluster ionizer when operating conditions are met through ION mode and CLEAN mode line. And using diagnosis line DATC monitor ionizer fault and store DTC. After DTC is stored then ionizer operation is stopped. ⑤ System monitor function, display When ignition ON ION mode is started for 2 sec (including control panel display) to check hardware. After ionizer control CLEAN mode and ION mode depending on control logic. ⑥ DTC condition - If diagnosis signal is input over 2sec (DTC is detected) ION and CLEAN mode operation are prohibited. - After ignition OFF DTC is eliminated automatically.( DTC : cluster ionizer abnormal) Cluster ionizer Cluster ionizer mode Signals Ion mode Clean mode OFF (-) ion activation (+,-) ion ION signal HI (12V) LOW (0V) CLEAN signal Ionizer Control Unit Ground IG 2 ION signal CLEAN signal Diagnosis signal Ionizer Control Unit Ground IG 2 ION signal CLEAN signal Diagnosis signal Signal Normal Abnormal Diagnosis signal Over 1.5V ( approx.5V) Less 1.5V CLEAN mode : CLEAN display ION mode : ION display Cluster ionizer operating lamp

Rear blower control Rear blower control DATC Unit Register Pin No To understand the rear blower control Material: Trainees textbook Method: Lecture Question Lead over: Lets have a look at the owner’s setting procedure . Circuit diagram Rear blower control Rear blower relay Register Rear blower motor DATC Unit Rear blower common Rear blower relay ON Rear blower S/W Register Pin No Description 1 M-HI 2 - 3 HI 4 LOW 1 2 3 4

Owner’s setting procedure Defroster logic control The procedure is almost same as existing model. At first, press the defroster button to select the air blowing mode to the front windshield glass. Next, keep to press A/C button and press the intake button more than 5 times within 3 seconds. When button signal inputs normally, the display screen on the control panel will blink at 3 times. Upon repeating this procedure one more time, it will be restored to the original status. Diagnosis on the control panel without scanner Keep to press OFF button and press MODE button for 4 times within 2sec. The stored (if exists) DTC will appear on the display screen. Material: Trainees textbook Method: Lecture Question Task Lead over: Lets have a look at the owner’s setting procedure To understand the DEF logic setting and temperature unit conversion procedure as well as the diagnosis method without the scanner in XM. Owner’s setting procedure Self diagnosis Push MODE button while pushing OFF (4times within 2 sec) Blinking all display (2times, 2Hz) Check the DTC on display Temperature unit conversion OFF button + AUTO button (3sec)

Owner’s setting procedure Temperature unit conversion Keep to press OFF button and press AUTO button for 3sec. Material: Trainees textbook Method: Lecture Question Task To understand the DEF logic setting and temperature unit conversion procedure as well as the diagnosis method without the scanner in TD. Owner’s setting procedure Defroster logic control 1 Defroster button A/C button + Intake button (5 times) Check the display screen (3 times blinking) 3 2