Air Conditioning System - Hev: Other Kia Optima III

Flange With Guide Pin

Check the new O-ring for damage (use only the specified) and lubricate by using compressor oil. Tighten the nut to specified torque.

Scheme 296

Note. T means tensile intensity, which is stamped on the head of bolt only numeral.

Handling tubing and fittings

The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and cause problems or serious damage.

The Following precautions must be observed

1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready so the system will not be left open any longer than necessary.
2. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.
3. All lines and components in parts stock should be capped or sealed until they are ready to be used.
4. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean and dry.

Scheme 297

Refrigerant System Service Basics

1. Since the electric compressor uses high-voltage, you should use PVE or POE oil which have high Volumetric Resistivity.
2. Do not use the same A/C recovery / charging station as conventional belt-driven compressors.

Refrigerant Recovery

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a) from the air conditioning system.

If accidental system discharge occurs, ventilate work area before resume of service.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

Scheme 298

Scheme 299

1. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to install the same amount of new refrigerant oil back into the A/C system before charging.

System Evacuation

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a) from the air conditioning system.

If accidental system discharge occurs, ventilate work area before resume of service.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

Scheme 300

1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using an R-134a refrigerant Recovery/Recycling/Charging System. (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)
2. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks (see «LEAK TEST»(ref-535715-S11109171082013031200000) .).
4. Remove the low pressure valve from the low-pressure service port.

System Charging

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a(R-134a) from the air conditioning system.

If accidental system discharge occurs, ventilate work area before resume of service.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

Scheme 301

1. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) as shown, following the equipment manufacturer's instructions.
2. Add the same amount of new refrigerant oil to system that was removed during recovery. Use only specified refrigerant oil. Charge the system with 19.4 ± 0.88 oz. (550 ± 25g) of R-134a refrigerant. Do not overcharge the system the compressor will be damaged.

Handling of Oil

1. The oil should be free from moisture, dust, metal powder, etc.
2. Do not mix with other oil.
3. The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC-134a Compressor Oil absorbs moisture very easily.)
4. The compressor oil must be stored in steel containers, not in plastic containers.

Compressor Oil Check

The oil used to lubricate the compressor is circulating with the refrigerant.

Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil.

Oil total volume in system

POE OIL: 3.8 ~ 4.5 oz. (115 ~ 135cc)

Compression Part

One of the scrolls is fixed, while the other orbits eccentrically without self-rotating, thereby to trap and pump refrigerant in the pockets between the scrolls.

Scheme 302

Motor Part

Convert electric power into a mechanical motion with Brushless DC Motor.

Scheme 303

Convert direct current to 3-phase alternating current and alter the compressor speed in cope with cooling demand.

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

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. Shut off the high voltage circuit. (Refer to «HYBRID CONTROL SYSTEM»(ref-535721-S23921223772013031200000) - «HIGH VOLTAGE SHUTOFF PROCEDURE»(ref-535721-S38559203892013031200000) )
3. Recover the refrigerant with a recovery/charging station. WARNING: If the PVE or POE oil of the system gets mixed with PAG oil, then dielectric breakdown due to decreased volumetric Resistivity can occur and inoperative A/C compressor may result, A/C compressor may not work.
4. Loosen the mounting bolts and then remove the under cover(A).
5. Loosen the mounting bolts and clip then remove the wheel house(A).
6. 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.
7. Disconnect the compressor low voltage connector and then remove 6 mounting bolts and the compressor(A).

Scheme 309

1. Make sure of the length of compressor mounting bolts, and then tighten it A-->B-->C-->D-->E-->F order. Tightening torque: 10~15 N.m (2.04~3.36 kgf.m, 7.37~11 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 105~125cc(3.7~4.4 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 on the container and seal it to avoid moisture absorption. WARNING: If the PVE or POE oil of the system gets mixed with PAG oil, then dielectric breakdown due to decreased volumetric Resistivity can occur and inoperative A/C compressor may result, A/C compressor may not work.

Scheme 310