Kia Sportage: Air conditioning System / Compressor Repair procedures

Kia Sportage QL (2015-2019) Service Manual / Heating,Ventilation And Air Conditioning / Air conditioning System / Compressor Repair procedures

Removal
1.
If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.
2.
Disconnect the negative (-) battery terminal.
3.
Recover the refrigerant with a recovery/charging station.
4.
Loosen the drive belt.
(Refer to Engine Mechanical System - " Drive Belt")
5.
Remove the discharge hose (A) after loosening the nut.
Tightening torque : 7.8 - 11.8 N.m ( 0.8 - 1.2 kgf.m, 5.8 - 8.7 Ib-ft)

6.
Remove the suction hose (A) after loosening the nut.
Tightening torque : 7.8 - 11.8 N.m ( 0.8 - 1.2 kgf.m, 5.8 - 8.7 Ib-ft)

  
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
7.
Disconnect the ECV connector (A).

8.
Remove the compressor assembly (A) after loosening the bolts.
Tightening torque : 20.00 - 32.95 N.m (2.04 - 3.36 kgf.m, 14.75 - 24.30 lb-ft)

[R Engine]

[Nu Engine]

[THETA Engine]

Installation
1.
Make sure that the compressor mounting bolt of the correct length is screwed in. Tighten the mounting bolts in the specified tightening order.
Tightening torque : 20.00 - 32.95 N.m(2.04 - 3.36 kgf.m, 14.75 - 24.30 lb-ft)
[R Engine]

[Nu Engine]

[THETA Engine]

2.
Install in the reverse order of removal.
When installing a new compressor, drain all the refrigerant oil from the removed compressor and measure its volume. Subtract the volume of drained oil from the original capacity to calculate the amount of compressor oil that needs to be drained from the new compressor (through the suction fitting).
Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage.
To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
Inspection
1.
Check the plated parts of the limiter & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the assembly.
2.
Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the pulley with a new one if it is noisy or has excessive play/drag.

Electronic Control Valve Compressor Inspection (KDS/GDS)
Compressor type: Fixed type compressor, External control valve, Internal control valve.
For fixed type and internal control valve, the compressor operation can be inspected by the clutch noise.
When it comes to External control valve, however, it cannot be checked in this way as it does not have a clutch.
So, ECV should be inspected by KDS/GDS in the following procedure:
1.
Connect KDS/GDS to the vehicle and select 'Air Conditioner Compressor Test (ECV type)'.
[ECV1]

2.
Make the vehicle ready as in the KDS/GDS instruction on the monitor. (Turn off A/C 'switch' only.)
[ECV2]

[ECV3]

3.
Check if other DTC codes are found before inspecting ECV compressor. If found, solve these problems first. Otherwise, press 'OK' button to continue.
  
Do not continue inspection if the following DTC codes are found: B124111, B124213, B167288, B168588, B168688, B168788.
[ECV4]

4.
Start inspection
[ECV5]

[ECV6]

  
Check for condenser fan operation when condition is changed to 'ECV running'.
  
Relief Valve will be operated if the condenser fan does not work due to over pressure in the compressor. The Relief Valve helps the air conditioning system to relieve pressure by releasing refrigerant and oil (closes valve when relieved).
※ Refill refrigerant and oil after operating Relief Valve.
※ Noise occurs during Relief Valve operation.
5.
Check the result of inspection.
[ECV7]

[ECV8]

6.
If the result shows to "Check", click "Check" and follow the instruction.

7.
Inspect ECV again from the first step.
Disassembly
1.
Remove the front tire [RH].
2.
Loosen the drive belt.
(Refer to Engine Mechanical System - " Drive Belt")
3.
Remove the clutch bolt (A) while holding the pulley with a clutch bolt remover (09977- 3R000).
Tightening torque : 15 ~ 21 N.m (1.53 ~ 2.14 kgf.m, 11.1 ~ 15.5 lb-ft)

4.
Loossen the limiter bolts and then remove the limiter & hub assembly (A).

5.
Remove the pulley (B) after removing the snap ring (A) with a snap ring plier.

  
Be careful not to damage the pulley and compressor during disassembly/reassembly.
Once the snap ring is removed, replace it with a new one.
6.
Reassemble in the reverse order of disassembly.
  
Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
Install a new snap ring, and make sure they are fully seated in the groove.
Make sure that the pulley turns smoothly after reassembly.
Compressor Description and operation
Description The compressor is the drive unit of the A/C system. Located on the side of the engine block, it is driven by the V-belt of the engine. The compressor changes low ...

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