Kia Niro: Air Conditioning System / Compressor Repair procedures

Removal
  

Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.

1.

If the compressor is marginally operable, run the engine, and let the air conditioning work for a few minutes, then shut the engine off.

2.

Disconnect the negative (-) battery terminal.

3.

Shut off the high voltage circuit.

(Refer to Heating,Ventilation, Air Conditioning - "High Voltage Shut-off Procedures")

4.

Recover the refrigerant with a recovery/charging station.

  

If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the A/C compressor may not work.

5.

Remove the engine room under cover.

(Refer to Engine Mechanical System - "Engine Room Under Cover")

6.

Disconnect the discharge hose (A) and suction hose (B) after loosening the nuts.

Tightening torque : 7.8 - 11.7 N·m (0.8 - 1.2 kgf·m, 5.7 - 8.6 lb·ft)

  

Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

7.

Disconnect the compressor connector (A) and high voltage connector (B).

  

Pull out the locking pin (A), and disconnect the high voltage connector by pressing the lever (B).

8.

Remove the compressor assembly (A) after loosening the bolts.

Tightening torque : 20.0 - 32.95 N·m(2.04 - 3.36 kgf·m, 14.75 - 24.30 Ib·ft)

9.

Remove the compressor high-voltage connector (A).

  

Pull the locking pin by pressing the lever (A) and remove the high-voltage connector.

Installation
1.

Make sure the compressor mounting bolt with the correct length is screwed in. Tighten the mounting bolts to the specified torque.

Tightening torque :

20.0 - 32.95 N·m (2.04 - 3.36 kgf·m, 14.75 - 24.30 Ib·ft)

2.

Install in the reverse order of removal, and note the following.

  

When installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure its mass. Then, subtract the volume of drained oil from 130 ± 10 g (4.58 ± 0.35 oz). The result is the amount of oil that should 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.

  

If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the A/C compressor may not work.

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