Air Conditioning System: Diagnosis Kia Optima II рестайлинг

REFRIGERANT LEAK TEST

Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when conducting service operations which are accompanied by disassembly or loosening or connection fittings.

Note. In order to use the leak detector properly, read the manual supplied by the manufacturer.

If a gas leak is detected, proceed as follows

1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage with a leak detector (A).
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.

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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.
5. Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug (C) or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
6. Disconnect the compressor clutch connector (A), and then remove 4 mounting bolts and the compressor.

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1. Make sure of the length of compressor mounting bolts, and then tighten it A-->B-->C-->D order. Tightening Torque : 2.04 ~ 3.36 kgf.m
2. Install in the reverse order of removal, and note these items.

1. 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 150cc(5.07 oz.) the result is the amount of oil you should drain from the new compressor (through the suction fitting).
2. 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.
3. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
4. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
5. 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.
6. Adjust the drive belt.
7. Charge the system and test its performance.

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1. Remove the center bolt (A) while holding the disc & hub assembly with a commercially available disc & hub assembly bolt remover; Special tool number 09977-29000. TORQUE : 10~15N.m (1.02~1.53kgf.m, 7.37~11lb.ft)
2. Remove the disc & hub assembly (A) and shim (gap washer) (B), taking care not to lose the shims. If the clutch needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the disc & hub assembly, and recheck its clearance.
3. If you remove the field coil, remove retainer ring (A) with retainer ring pliers. NOTE: 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.
4. Remove the screw (A) from the field coil ground terminal. Remove the retainer ring (B) and then remove the field coil (C) from the shaft with a puller. Be careful not to damage the coil and compressor.
5. 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.

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1. Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the clutch set.
2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag.
3. Measure the clearance between the pulley (B) and the disc & hub assembly (A) all the way around. If the clearance is not within specified limits, remove the disc & hub assembly and add or remove shim (gap washer) as needed to increase or decrease clearance. Clearance : 0.45 ± 0.1mm (0.018 ± 0.004 in.) NOTE: The shims (gap washers) are available in seven thicknesses: 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm and 1.3mm.
4. Check operation of the magnetic clutch.

Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the compressor body. Check the magnetic clutch operating noise to determine the condition.

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INSPECTION

1. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with compressed air. If bent, gently bend them using a screwdriver or pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.

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1. Recover the refrigerant with a recovery/recycling/charging station.
2. Disconnect the negative (-) battery terminal.
3. Remove the radiator. (Refer to «RADIATOR»(ref-357427-S12268467782010032300000) ).
4. Remove 2 bolts, and then remove the condenser (A) by lifting it up. Be careful not to damage the radiator and condenser fins when removing the condenser.
5. Install in the reverse order of removal, and note these items : If you're installing a new condenser, add refrigerant oil ND-OIL8. 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. Be careful not to damage the radiator and condenser fins when installing the condenser. Be sure to install the lower mount cushions of condenser securely into the holes. Charge the system, and test its performance.

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1. Remove the condenser, and then remove the bottom cap (B) with L wrench (A) from the condenser. TORQUE: 20~25N.m (2.0~2.5kgf.m, 14.5~18.2lb-ft)
2. Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged bottom cap filter.
3. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
4. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed to air for use.
5. Install the new bottom cap to the condenser.

Note. Always replace the desiccant and bottom cap at the same time. 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. Be careful not to damage the radiator and condenser fins when installing the condenser. Be sure to install the lower mount cushions of condenser securely into the holes. Charge the system, and test its performance.

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1. Ignition "OFF"
2. Disconnect evaporator temperature sensor.

Using the multi-tester, Measure resistance between terminal "1" and "2" of evaporator temperature sensor.

RESISTANCE SPECIFICATION

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1. Remove the crash pad center lower cover. (Refer to «CRASH PAD»(ref-357465-S42759464242010032300000) )
2. Remove the evaporator sensor connector(A).
3. Remove the evaporator temperature sensor(B), by pulling it after rotating 90° in a counterclockwise direction.
4. Installation is the reverse order of removal.

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1. Ignition "ON".
2. Blow air with changing temperature to the in car sensor air inlet. Measure sensor resistance between 2 and 4 terminals.

Specification

SPECIFICATION CHART

Note. In car sensor is negative type thermistor resistance will rise with lower temperature, and reduce with higher temperature.

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1. Disconnect the negative (-) battery terminal.
2. Remove the center facia panel. (Refer to «CRASH PAD»(ref-357465-S42759464242010032300000) ).
3. Disconnect the connector of in-car sensor (A). Loosen the mounting 2 screws and then remove the in-car sensor (B).
4. Installation is the reverse order of removal.

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1. Ignition "ON".
2. Using the scan tool.
3. Emit intensive light toward photo sensor using a lamp, and check the output voltage change.
4. The voltage will rise with higher intensive light and reduce with lower intensive light.

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1. Disconnect the negative (-) battery terminal.
2. Using a suitable tool that will not damage the sensor, crash pad, or windshield remove the photo sensor (B) from the center of defrost nozzle (A).
3. Install in the reverse order of removal.

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1. Ignition "ON".
2. Using the scan tool.
3. Check the frequency of humidity sensor between terminals 2 and 3. HUMIDITY SENSOR FREQUENCY REFERENCE Humidity (%) Frequency between terminals 2 and 3 (Hz) 30 6976 ± 5% 50 6728 ± 5% 60 6600 ± 5% 70 6468 ± 5% 80 6330 ± 5% 90 6186 ± 5%
4. If the measured resistance is not specification, substitute with a known-good humidity sensor and check for proper operation.
5. If the problem is corrected, replace the Humidity sensor.

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1. Disconnect the negative (-) battery terminal.
2. Remove the center facia lower panel. (Refer to «CRASH PAD»(ref-357465-S42759464242010032300000) )
3. Disconnect the humidity sensor connector.
4. Loosen 2 screws and then remove the humidity sensor (C).
5. Installation is the reverse order of removal.