Kia air conditioning diagnosis

ACD Course Introduction Kia Air Conditioning Diagnosis SERVICE TRAINING SAFETY Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the repair There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or caution to each Accordingly, anyone who departs from the instruction provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools, or parts The following list contains general warnings that should always be followed while working on a vehicle • Always wear safety glasses for eye protection • Use safety stands whenever a procedure requires underbody work • Be sure ignition switch is always off unless otherwise specified by a procedure • Set the parking brake when working on the vehicle • Operate the engine only in a well ventilated area • Keep clear of moving parts when engine is running • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler • Do not smoke while working on a vehicle KIA AIR CONDITIONING DIAGNOSIS COURSE INTRODUCTION WELCOME TO: Kia Air Conditioning Diagnosis • Hands-on practice with Kia diagnostic tools • Review of available resources Course length is one day ACD-1 This course provides an opportunity for observed hands-on practice diagnosing the cause of Kia air conditioning complaints using various types of tests and diagnostic tools In preparation to meet this goal, you will: • Identify normal operation of a Kia air conditioning system • Learn to use the Kia 5-step diagnosis process to locate faults • Gain experience using an electronic (halogen) leak detector to help isolate faults • Gain experience using mechanical and pressure tests to isolate faults In addition, you will gain hands-on experience using an A/C recovery, recycling, and recharging station As an addendum to this course, you will be given the opportunity to use the ASE Refrigerant Recovery and Recycling Review and Quiz to obtain an ASE certification in that area The length of the course is one day COURSE GOAL To provide Kia technicians with the skills and knowledge required to diagnose and repair a vehicle that has an air conditioning system malfunction ACD-2 To provide Kia technicians with the skills and knowledge required to diagnose and repair a vehicle that has an air conditioning system malfunction PREREQUISITES Successful completion of the Kia Product Familiarization course ASE A7, or equivalent, is highly recommended c o u r s e g u i d e AC D KIA AIR CONDITIONING DIAGNOSIS MODULAR FORMAT • Helps you focus your efforts in the areas that are of the most value to you ACD-3 As a Kia service professional, you understand the importance of staying current with today’s complex automotive technology The amount of training that a technician needs depends on factors like technical background, product knowledge and practical experience To meet your needs, we have developed a modular training system to help you focus your efforts in the areas that are of the most value to you TWO TYPES OF MODULES Student Learning Guide and Workbook: • Explains theory • Can be used for self-study Guided Practice: • Provides hands-on experience • Helps develop troubleshooting skills ACD-4 Student Learning Guide and Workbook: These modules explain subjects from basic concepts to the most complex technology we offer Obtaining a working knowledge of any system or component is a prerequisite to effectively diagnose system malfunctions These modules may also include classroom exercises that you will complete as a group Guided Practice: These modules provide hands-on experience, building on the theory and diagnosis topics covered earlier These modules also help you develop troubleshooting skills and often involve the use of service manuals, ETM’s, technical service bulletins, newsletters, and other resources as an integral approach to your overall diagnostic strategy c o u r s e g u i d e AC D KIA AIR CONDITIONING DIAGNOSIS MODULE SYMBOLS VIDEO When you see this symbol, view the appropriate video segment for important concepts or procedures ACTIVITY Activities support critical learning objectives Performing these procedures will help you master the material REFERENCE FEEDBACK This symbol shows when you must refer to additional publications to complete the questions or module activity Most modules contain a Self-Test or an Instructor Signoff to give you feedback on your strengths and weaknesses Gauge your level of expertise by your ability to answer the questions and instructor's feedback Review appropriate areas as needed ACD-5 Several symbols have been designed to keep you on track as you complete each module These symbols are shown in the illustration above COURSE SCHEDULE • Course Activities Guide • Final Test ACD-6 When you attend a modular training course, each module will be part of a structured learning plan illustrated in the Course Activities Guide that is on the next page After completing the required modules, you will take a Final Test to verify your understanding of the course subject areas that were covered in the course c o u r s e g u i d e A c D KIA AIR CONDITIONING DIAGNOSIS KIA AIR CONDITIONING DIAGNOSIS - COURSE ACTIVITY GUIDE TIME LOCATION T YPE INST SUBJECT MATTER 8:00 - 8:30 Classroom Discussion Introductions & Course Goals 8.30 - 9:30 Classroom Discussion/Video Kia Air conditioning Systems 9:30 - 9:45 Break 9:45 - 10:15 Classroom Discussion/Video Kia Air conditioning Systems (cont’d) 10:15 - 12:00 Techniques Shop Activity Kia A/C System Diagnostic 12:00 - 1:00 Lunch 1:00 - 1:30 Classroom Review/Quiz ASE Refrigerant Recovery & Recycling 1:30 - 2:30 Shop Activity Kia A/C System Servicing 2:30 - 2:45 Break 2:45 - 4:00 Shop Activity Kia A/C System Servicing ACD-7 GETTING THE MOST OUT OF THE COURSE • Take notes and make drawings Use the course materials in any way that will help you remember the material Make notes or drawings on these materials to help you remember details • Work as a team • Learn from mistakes • Ask questions • Be an active participant ACD-8 One of Kia’s main goal is to provide as much individual instruction as possible If you not understand something in the classroom, ask your instructor to clarify the point During hands-on practice sessions, you will often be part of a working team You will only learn from the experience if you actively participate This training course is an opportunity to learn advanced skills successfully in a controlled environment under the guidance of a trained Kia instructor Have a good experience here, and return to your dealership with confidence in your own abilities as a trained Kia professional c o u r s e g u i d e AC D KIA AIR CONDITIONING DIAGNOSIS COURSE CREDIT • Guided Practice = 65% Course credit will be granted by a Kia Service Training Instructor when all of the criteria for course completion has been met • Final test = 25% • Class participation = 10% Total = 100% • 80% required for course credit ACD-9 Because our technical training is performancebased, hands-on practice will make up 65% of your course credit Each Guided Practice module lists specific performance objectives that are the basis for scoring The instructor will observe and evaluate your performance, coaching you when necessary Additional factors that may affect this score are safe and appropriate use of tools and equipment and following written and verbal instructions Each Guided Practice Module is assigned a relative “point” value, depending on the difficulty of the material The final test, administered by the instructor, makes up 25% of your course credit The instructor will evaluate the degree to which you contribute to discussions, offer your experience, or simply ask questions about something you don’t understand Participation also takes into account your professional conduct, and working with teammates during classroom and shop practice activities This counts for 10% of your course credit The sum of the above scores will determine your course achievement performance A minimum score of 80% is required for course credit c o u r s e g u i d e A c D KIA AIR CONDITIONING DIAGNOSIS NOTES _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ c o u r s e g u i d e AC D KIA AIR CONDITIONING DIAGNOSIS NOTES _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ c o u r s e g u i d e A c D KIA AIR CONDITIONING DIAGNOSIS NOTES _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ c o u r s e g u i d e AC D AC-3 Kia A/C System Servicing Guided Practice SERVICE TRAINING SAFETY Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the repair There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work This module cannot possibly anticipate all such variations and provide advice or caution to each Accordingly, anyone who departs from the instruction provided in this module must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools, or parts The following list contains general warnings that should always be followed while working on a vehicle • Always wear safety glasses for eye protection • Use safety stands whenever a procedure requires underbody work • Be sure ignition switch is always off unless otherwise specified by a procedure • Set the parking brake when working on the vehicle • Operate the engine only in a well ventilated area • Keep clear of moving parts when engine is running • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler • Do not smoke while working on a vehicle KIA A/C SYSTEM SERVICING Kia A/C DIAGNOSTIC TECHNIQUES After completing this module, you will be able to properly service a Kia air conditioning system using the A/C Refrigerant Handling Station Knowing how to use these skills will help you service a Kia air conditioning system faster and more effectively LEARNING OBJECTIVES MODULE DIRECTIONS • Properly connect an A/C Refrigerant Handling Station to a Kia vehicle • Recover the refrigerant and compressor oil from a Kia air conditioning system • Evacuate a Kia air conditioning system • Add the proper amount of compressor oil to a Kia air conditioning system • Recharge an air conditioning system • Verify that an air conditioning system is operating properly after recharging Carefully follow the procedures and answer the questions in this module Study each illustration as you read the material Feel free to ask questions any time something is not clear When you have completed all of the activities, see your instructor for module sign off THINGS YOU WILL NEED • 2000 or later Sephia or Sportage with A/C • Service Manual for the vehicle • A/C Refrigerant Handling Station • Thermometer • Graduated container with o-ring or other marking device for oil measurement • Face Shield or Safety Goggles • Gloves m o d u l e AC - KIA A/C SYSTEM SERVICING WARNING REFERENCE m o d u l e AC - READ BEFORE STARTING • Always connect an exhaust hose to the vehicle before running the engine or run the engine only in a well ventilated area • To protect yourself against serious injury, while working in the engine compartment with the engine running, be careful not to touch the cooling fan(s) or other moving components • To protect yourself, you must wear eye protection and gloves any time you are working around an A/C system that has a suspected leak • When connecting or disconnecting the A/C refrigerant handling station, be sure to wear eye protection and gloves just in case you accidentally create a refrigerant leak • When recharging an A/C system, NEVER open the high side valve on the storage tank or manifold on the handling station with the engine running and the A/C turned ON High side pressure is usually higher than the pressure in the storage tank and can cause the tank to explode If you need to charge the system with the engine running charge the system through the low side only The photos in this module depict a Sportage If you are assigned a Sephia for these activities, refer to the service manual to locate the service ports and any other information or illustrations that you might need When in doubt, ask your instructor! KIA A/C SYSTEM SERVICING ACTIVITY Activity - Preparing the Vehicle In this activity, you will prepare the vehicle for A/C system servicing Open the hood Roll down the windows Connect an exhaust hose to the vehicle Start the engine and warm it to normal operating temperature Move the temperature control to full cold Set the fan speed to Turn the A/C switch to ON Allow the A/C system to run for about minutes, then turn the A/C switch OFF Turn the ignition switch to OFF WARNING When connecting or disconnecting the A/C refrigerant handling station, be sure to wear eye protection and gloves just in case you accidentally create a refrigerant leak 10 Remove the primary seal caps from the low side and high side service ports 11 Ensure that the coupler valves are in the OFF position (fully counterclockwise) 12 Connect the blue pressure hose to the low side service port 13 Connect the red pressure hose to the high side service port m o d u l e AC - 3 KIA A/C SYSTEM SERVICING 14 Open both of the coupler valves 15 Read the low and high side gauges There must be pressure to recover the refrigerant FEEDBACK ACTIVITY Notify your instructor as soon as you have finished this activity Activity - Refrigerant Recovery In this activity, you will recover the refrigerant and compressor oil from the A/C system Open both manifold valves on the handling station Open both valves on the handling station storage tank Plug the handling station power cord into a 110 volt outlet Turn the MAIN POWER switch to ON m o d u l e AC - KIA A/C SYSTEM SERVICING Press the RECOVER key on the handling station’s control panel Note: The unit will automatically clear itself of refrigerant and start recovering the refrigerant from the vehicle The unit will also display the refrigerant amount as it is recovered (in lbs or kgs.), then it will display CPL and shut off when recovery is complete Watch the gauges for minutes, if pressure does not increase, recovery is complete If pressure rises, press the HOLD/CONT key and repeat until pressure holds steady for minutes Open the oil drain valve and drain the oil into an empty graduated container Did you know? If you replace an air conditioning component because of internal failure, you must use fresh oil when recharging the A/C system Leave the unit’s MAIN POWER switch ON FEEDBACK Notify your instructor as soon as you have finished this activity m o d u l e AC - KIA A/C SYSTEM SERVICING ACTIVITY Activity - A/C System Evacuation In this activity, you will evacuate the A/C system to remove any air and moisture that may be trapped in the system Remember, evacuating the system does not remove dirt and foreign material from the system Verify that both manifold valves are still open Press the SHIFT/RESET key until the message “PROGRAM VACUUM MINUTES” appears in the display Press the VACUUM key; The display counts down the vacuum time The unit will display “CPL” when evacuation is complete The low side pressure gauge should read about 28 to 29 inches Hg on the vacuum portion of the low-side gauge Did you know? You can check for A/C system leaks during evacuation by pressing the “HOLD/CONT” key after minutes and watching the vacuum gauge If the gauge drops to zero, the system has a major leak You can also temporarily close the manifold valves and watch the vacuum gauge for a steady reading If the vacuum bleeds off, a minor leak is indicated FEEDBACK m o d u l e AC - Notify your instructor as soon as you have finished this activity KIA A/C SYSTEM SERVICING ACTIVITY Activity - Add Lubricating Oil In this activity, you will add the correct amount of lubricating oil to the A/C system Add ounces of PAG oil to an empty graduated container This ensures that the container won’t run dry and the system won’t ingest air while you are adding oil Slide an o-ring or rubber band down to the ounce mark on the graduated container This is the amount that will remain in the container when you have finished adding oil to the system Add the oil that you extracted from the vehicle’ A/C system to the container Slide the container over the pick-up tube and thread it onto the handling station With the A/C system still under a vacuum from evacuation, open (turn to ON) the oil injection valve above the container Close (turn to OFF) the valve when the level in the container drops to the ounce mark Do Not overfill! FEEDBACK Notify your instructor as soon as you have finished this activity m o d u l e AC - KIA A/C SYSTEM SERVICING ACTIVITY Activity - Recharge the A/C System In this activity, you will add the correct amount of refrigerant to the A/C system WARNING When recharging an A/C system, NEVER open the high side valve on the storage tank or manifold on the handling station with the engine running and the A/C turned ON High side pressure is usually higher than the pressure in the storage tank and can cause the tank to explode If you need to charge the system with the engine running charge the system through the low side only REFERENCE Refer to Section 62 of the service manual under “Other Specifications” and fill in the charged amount of refrigerant in the space below grams Verify that both manifold valves are open Verify that both tank valves are open m o d u l e AC - KIA A/C SYSTEM SERVICING Press the SHIFT/RESET key until the display shows “PROGRAM” and 0.00 Verify that the display is in KG Did you know? For this activity, if the display reads in lbs., change the position of the lb./kg switch on the rear of the station, then turn the power switch OFF then back ON If your station does not have this switch, refer to the operator’s manual Using the keyboard, enter the charge amount in hundredths of a kilogram For example, if the charge amount is 700 grams, enter 070 The display should read 0.70 KG Press the ENTER key, followed by the CHG key The display will count down to zero, then change to “CPL” FEEDBACK Notify your instructor as soon as you have finished this activity m o d u l e AC - KIA A/C SYSTEM SERVICING ACTIVITY Activity - Verify A/C System Performance In this activity, you will verify that the A/C system is operating properly WARNING NEVER open the high side valve on the storage tank or manifold on the handling station with the engine running and the A/C turned ON High side pressure is usually higher than the pressure in the storage tank and can cause the tank to explode If you need to charge the system with the engine running charge the system through the low side only Close both manifold valves Close both valve on the storage tank Verify that an exhaust hose is connected to the vehicle Start the vehicle and let it warm up to normal operating temperature Configure the A/C system for maximum cooling Insert the thermometer into one of the face outlets After minutes, record the thermometer reading in the space below °F 10 m o d u l e AC - KIA A/C SYSTEM SERVICING Did the thermometer indicate that the A/C system in operating properly (35°-45°F)? YES NO (circle one) Have an assistant run the engine at a steady 1,500 to 2,000 rpm while you read the low and high side gauges on the handling station 10 Record the gauge readings in the spaces below Low Side Pressure High Side Pressure _ 11 Compare the low side gauge and high side gauge readings to the service manual specifications 12 Were the low and high side pressure readings within the range listed in the service manual? YES NO (circle one) 13 Allow the engine to return to idle 14 With the engine still running, close the high side coupler valve 15 Open both manifold valves on the handling station m o d u l e AC - 11 KIA A/C SYSTEM SERVICING 16 When both gauges read minimum pressure, close the low side coupler valve 17 Close both manifold valves on the handling station 18 Disconnect the pressure hoses from the service port 19 Install the primary seal caps on the low side and high side service ports 20 Turn the ignition switch OFF 21 Turn OFF the MAIN POWER switch on the handling station 22 Return the workstation to the condition it was in when you arrived FEEDBACK Notify your instructor as soon as you have finished this activity INSTRUCTOR SIGN-OFF 12 m o d u l e AC - Initials Objective _ Prepare a Kia vehicle for refrigerant recovery _ Recover refrigerant and compressor oil _ Evacuate the A/C system _ Add the proper amount of compressor oil _ Recharge the A/C system _ Verify A/C system performance No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc KMA reserves the right to make changes in the descriptions, specifications or procedures without prior notice or obligation Copyright © 2000 Kia Motors America, Inc Corporate Service Training Department KIA MOTORS AMERICA, INC 4/00 [...]... catalytic converter and muffler • Do not smoke while working on a vehicle KIA AIR CONDITIONING SYSTEMS KIA AIR CONDITIONING SYSTEMS Upon completion of this module, you will be familiar with the unique design characteristics that affect performance, diagnosis, and maintenance of Kia air conditioning systems Knowing how a Kia air conditioning system is designed to operate will help you diagnose Carefully... how an air conditioning system is designed to function • Identify each of the three sub-systems used in an air conditioning system • Identify each of the operating components that are used in Kia air conditioning systems and describe their function • Identify the function of each electrical signal used by the air conditioning system • Identify the various types of tests used to isolate Kia air conditioning. .. that occupants are more comfortable at all times • Occupants should be more comfortable at all AC1-2 times AIR CONDITIONING SUB-SYSTEMS AC1-3 The air conditioning system can be divided into three sub-systems: • Refrigeration system • Cooling system • Air distribution system 2 module AC-1 KIA AIR CONDITIONING SYSTEMS Refrigeration System • Consists of: - A/C Compressor The refrigeration system consists... stopped or moving slowly, the condenser and radiator cooling fans help the air intake system direct outside air through the condenser and radiator module AC-1 15 KIA AIR CONDITIONING SYSTEMS AIR DISTRIBUTION SYSTEM OPERATION AC1-24 The air distribution system controls the desired path, temperature, and volume of conditioned air entering or being re-circulated about the passenger compartment The evaporator... from Kia Motors America, Inc KMA reserves the right to make changes in the descriptions, specifications or procedures without prior notice or obligation Copyright © 2000 Kia Motors America, Inc Corporate Service Training Department KIA MOTORS AMERICA, INC 4/00 AC-1 Kia Air Conditioning Systems Student Learning Guide and Workbook SERVICE TRAINING SAFETY Appropriate service methods and proper repair procedures... module AC-1 3 KIA AIR CONDITIONING SYSTEMS • Material applies to all Kia Motors America vehicles • Exceptions noted, where applicable APPLICATION The material in this learning guide applies to all Kia Motors America vehicles Exceptions will be noted as appropriate AC1-7 • A/C system is always important to occupants: • In warm weather: - Removes moisture - Cools incoming air or recirculated air • In cold... that the heater core can warm dry air This provides a more comfortable environment for the passengers, speeds up defogging the windows and helps keeps them from fogging up again On model year 2000 and later vehicles, the air conditioning will come on anytime “defrost” has been selected with the mode control KIA AIR CONDITIONING SYSTEMS PRINCIPLES OF REFRIGERATION • A/C diagnosis requires basic understanding... air conditioning system AC1-1 MODULE DIRECTIONS THINGS YOU WILL NEED VIDEO illustration as you read the material Feel free to ask questions any time something is not clear Be sure to answer the SELF-TEST questions at the end of the module 1998 or later Sephia and Sportage service manuals and ETMs NOTE: Before beginning this module, be sure to view the Kia A/C Diagnosis Video module AC-1 1 KIA AIR CONDITIONING. .. hose and the high port pressure is on cooler pipe #1 • Both are quick disconnect type module AC-1 21 KIA AIR CONDITIONING SYSTEMS Heater Control Unit The heater control unit provides a mounting platform for the air temperature control, mode control, fan speed control, air intake control, and the air conditioning ON/OFF switch Over the years a variety of controls have been used on Sephia and Sportage... mercury Now that you have reviewed the basics, let’s put it all together to see how an A/C system works 10 module AC-1 KIA AIR CONDITIONING SYSTEMS REFRIGERATION SYSTEM OPERATION HEAT REMOVED AC1-19 All Kia vehicles use Cycling Clutch, Thermostatic Expansion Valve (CCTXV) type air conditioning systems In this type of system, the A/C compressor has a fixed displacement The A/C compressor clutch is turned ... not smoke while working on a vehicle KIA AIR CONDITIONING DIAGNOSIS COURSE INTRODUCTION WELCOME TO: Kia Air Conditioning Diagnosis • Hands-on practice with Kia diagnostic tools • Review of available... subject areas that were covered in the course c o u r s e g u i d e A c D KIA AIR CONDITIONING DIAGNOSIS KIA AIR CONDITIONING DIAGNOSIS - COURSE ACTIVITY GUIDE TIME LOCATION T YPE INST SUBJECT MATTER... the Kia A/C Diagnosis Video module AC-1 KIA AIR CONDITIONING SYSTEMS • Conditions air coming into the passenger compartment by: - Cooling - Heating - Dehumidifying - Filtering OVERVIEW The air conditioning,