Automatic A/c-Heater Systems: Other Kia Sorento I

MALFUNCTION CAUSES AND REMEDIES

Note. Numbers indicate checking/inspection order.

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WHEN HANDLING REFRIGERANT

1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When handling the refrigerant, be sure to wear gloves.
2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the refrigerant splashes into your eyes, wash them with clean water immediately.
3. The R-134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature is below 52°C (126°F).
4. An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-134a, upon coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only the recommended lubricant for R-134a systems. If lubricants other than the recommended one are used, system failure may occur.
6. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be observed: When removing refrigerant components from a vehicle, immediately cap the components to prevent from the entry of moisture. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the components. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from taking on moisture. Use the recommended lubricant from a sealed container only.
7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.

WHEN REPLACING PARTS ON A/C SYSTEM

1. Never open or loosen a connection before discharging the system.
2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
3. Do not remove the sealing caps from a replacement component until it is ready to be installed.
4. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil before making the connection.

FLANGE WITH GUIDE PIN

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

Note. T means tensile intensity, which is stamped on the head of the bolt, next to the number.

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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 rebend formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including the refrigerant dispensing manifold, the manifold gauge set and test hoses, should be kept clean and dry.

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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 resuming service.

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

1. Connect a R-134a refrigerant Recovery/Recycling/Charging System to the high-pressure service port and the low-pressure service port, 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 resuming service.

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

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1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using a 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 a R-134a refrigerant Recovery/Recycling/Charging System to the high-pressure service port and the low-pressure service port as shown in illustration, following the equipment manufacturer's instructions.
3. If the low-pressure does not reach more than 93.3 kPa (700 mm Hg, 27.6 in. Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks. See «REFRIGERANT LEAK TEST»(ref-168977-S04696499052004122000000) .

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

Connect a R-134a refrigerant Recovery/Recycling/Charging System to the high-pressure service port and the low-pressure service port, as shown in illustration, following the equipment manufacturer's instructions.

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Add the same amount of new refrigerant oil to system that was removed during recovery. Use only FD46XG refrigerant oil.

Charge the system with 600 +/- 25 g (21.16 +/- 0.88 oz.) of R-134a refrigerant. Do not overcharge the system the compressor will be damaged.

STANDARD VALUE

If cooling cycle is operating normally, the manifold gauge set reading will be about 1.5-2.0 kg/cm 2 (21-28 psi) for the low pressure side and about 14.5-15 kg/cm 2 (206-213 psi) for the high pressure side. Inlet temperature should be 30-35°C (80-95°F), with the engine at 2,000 RPM, maximum cooling selected, and the blower on highest level.

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CHECKING THE CLUTCH AIR GAP

1. Check the air gap between the clutch hub and pulley contact surface using a feeler gauge. Clutch air gap : 0.35-0.65 mm (0.0138-0.0256 in)
2. Check the gap around the pulley at 3 points.
3. If the clutch air gap is outside the normal range, correct it using a shim of proper size.

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COMPRESSOR OIL

Oil lubricates the compressor and circulates in the system while the compressor is operating. Whenever replacing any component of the system, or when a large amount of gas leakage occurs, add oil to maintain the original total amount of oil.

HANDLING OF OIL

1. The oil should be free from moisture, dust, metal filings, etc.
2. Do not mix oils.
3. The moisture content in the oil increases when exposed to the air for prolonged periods. After use, seal the container immediately.

CHECKING AND ADDING OF COMPRESSOR OIL LEVEL

In order to add oil to an operating compressor, check the compressor oil using the following procedure

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1. Stop the engine, discharge the refrigerant, and dismantle the compressor from the vehicle.
2. Pour oil from the system line outlet. NOTE: If the compressor is cold, sometimes it can be hard to drain the oil. Warm the compressor to about 40-50°C (104-122°F) to drain the oil.
3. Check the volume of the discharged oil. If it is less than 70 cc (4.27 in 3 ), it means there is a small leak. Perform the leakage test on each system connection, and repair or replace faulty parts if necessary.
4. Check the oil for contamination and replenish the oil level in the following procedure: When oil is clean. If the oil is contaminated, determine cause of contamination and repair as necessary.

CHECKING FOR REFRIGERANT LEAKS

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.
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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CHECK RESISTANCE OF THE SENSOR

Note. In car sensor is a negative type thermistor. Resistance will rise with lower temperatures, and reduce with higher temperatures.

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SENSOR OUTPUT

Tolerance : 2%

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CHECKING MOTOR

Connect the battery voltage and check the blower motor rotation.

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1. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2.
2. Select the control switch to raise voltage until high relay operates.