Kia Cadenza: Air Conditioning System / Compressor Repair procedures

Kia Cadenza YG 2016-2024 Service Manual / Heating,Ventilation, 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 cable from the battery.
3.
Recover the refrigerant with a recovery/charging station.
4.
Loosen the drive belt.(Refer to EM group-Drive belt)
5.
Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

6.
Remove the engine room front under cover (A) by loosening the mounting bolts.

7.
Remove the engine room right side under cover (A) by loosening the mounting bolts.

8.
6. Disconnect the compressor clutch connector (A), and then remove 4 mounting bolts and the compressor(B).

Installation
1.
Make sure of the length of compressor mounting bolts, and then tighten it A→B→C→D order.

Tightening torque :
20.0~32.9N.m (2.04~3.36kgf.m, 14.7~24.3 lb-ft)

2.
Install in the reverse order of removal, and note these items
If you''re installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure its volume, Subtract the volume of drained oil from 120cc(4.20 oz.) the result is the amount of oil you should drain 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
Inspection
1.
Check the plated parts of the limiter assembly (A) for color changes, peeling or other damage. If there is damage, replace the limiter assembly.
2.
Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the limiter assembly with a new one if it is noisy or has excessive play/drag.

Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately.
Adjust the drive belt.
Charge the system and test its performance.
External Control Valve Compressor Inspection (GDS)
Compressor type: Fixed type compressor, External control valve, Internal control valve.
In cases of fixed type and internal control valve, it is possible to inspect compressor''s operation with clutch noise.
When it comes to External control valve, however, it cannot be checked in this way bacause it doesn''t have a clutch.
So, ECV should be inspected with GDS as below.
1.
Connect GDS to the vehicle and select ''Aircon Compressor Test(ECV type)''
[ECV1]

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

[ECV3]

3.
Check if other DTC codes are found before inspect ECV compressor. If so, solve that problems first. If not, press ''OK'' button to continue.
   
Do not continue inspection if these DTC codes are found: B1241, B1242, B1672, B1685, B1686, B1687
[ECV4]

4.
Start inspection
[ECV5]

[ECV6]

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

[ECV8]

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

7.
Inspect ECV again from the first step.
Disassembly
1.
Disconnect the negative cable from the battery.
2.
Remove the front right tire(A) from front hub.

Tightening torque:
88.2~107.8N.m (9.0~11.0kgf.m, 65.0~79.5 lb-ft)

3.
Separate the front portion of the front wheel guard (A) from the wheel base.

4.
Remove the engine room front under cover (A) by loosening the mounting bolts.

5.
Remove the center bolt (A) while holding the limiter assembly with a commercially available limiter assembly bolt remover, Special tool number 09977-3R000.

Tightening torque:
8.8~13.7N.m (0.9~1.4kgf.m, 6.5~10.1 lbf.ft)

6.
Remove the dlimuter assembly (A) and shim (gap washer), taking care not to lose the shims.

Tightening torque:
4.9~6.9N.m (0.5~0.71kgf.m, 3.6~5.1 lbf.ft)

7.
Remove the drive belt.
(Refer to EM group - "Timing Chain")
8.
Remove retainer ring (A) with retainer ring pliers and then remove the pulley(B).

   
Be careful not to damage the pulley (B) and compressor during removal/installation.
Once retainer ring (A) is removed, replace it with a new one.
9.
Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
Install new retainer rings, and make sure they are fully seated in the groove.
Make sure that the pulley turns smoothly after its reassembled.
Compressor Components and Components Location
Components 1. Screw2. Blot3. Limiter Assembly4. Retainer Ring5. Pulley6. Compressor Assembly ...

Condenser Components and Components Location
Component Location ...

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