Kia Optima: Air Conditioning System / Compressor

Precautions for using the plastic pulley

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.

Disconnect the negative (-) battery terminal.

Recover the refrigerant with a recovery/charging station.

Remove the engine room under cover.

G 2.0 NU MPI (Refer to Engine Mechanical System - "Engine Room Under Cover")

G 2.5 GDI THETA II (Refer to Engine Mechanical System - "Engine Room Under Cover")

Loosen the drive belt.

G 2.0 NU MPI (Refer to Engine Mechanical System - "Drive Belt")

G 2.5 GDI THETA II (Refer to Engine Mechanical System - "Drive Belt")

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.

Press the lock pin and separate the compressor connector (A).

Loosen the mounting bolts and remove the compressor assembly (A).

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

Install in the reverse order of removal.

• If you install 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. The result is the amount of oilcompressor 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, R-1234yf 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.

Check the plated parts of the limiter & hub assembly for color changes, peeling or other damage. If there is damage, replace the assembly.

Check the pulley (A) 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.

Connect KDS to the vehicle and select 'Aircon Compressor Test(ECV type)'

[ECV1]

Make the vehicle ready as the KDS instruction on the monitor. (Turn off A/C 'switch' only)

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

Start inspection

Check if condenser fan is operating when condition is changed to 'ECV running'

Relief valve will operate if condenser fandoesn't work due to overpressure in thecompressor. It helps the airconditiong system torelieve by releasing refrigerant and oil (losed ifrelieved). ※ Refill refrigerant and oil after operation of relief valve ※ Noise occurred when relief valve is in operation

Check the result of inspection.

[ECV7]

[ECV8]

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

Inspect ECV again from the first step.

Remove the front tire [RH].

Remove the engine room under cover.

G 2.0 NU MPI (Refer to Engine Mechanical System - "Engine Room Under Cover")

G 2.5 GDI THETA II (Refer to Engine Mechanical System - "Engine Room Under Cover")

Remove the clutch bolt (A) while holding the pulley with a clutch bolt remover (09383-59100).

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

Remove the pulley (A) after removing the snap ring 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.

Reassemble in the reverse order of disassembly.