Kia_Sephia_Rio_Spectra_Optima_1998-2006

Compressor

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Removal & Installation



1.5L And 1.6L Engines
  1. If not equipped with power steering, loosen the tension pulley tightening bolt A, and then remove the drive belt after loosening the tension adjusting bolt B.
  2.  
  3. If equipped with power steering, loosen the bolt A, B ,C and then remove the drive belt after loosening the tension adjusting bolt D.

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    Fig. Belt removal-without power steering



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    Fig. Belt removal -with power steering

  4.  
  5. Discharge the refrigerant, as outlined in this section.
  6.  
  7. Disconnect the discharge and suction hoses.
  8.  
  9. Unfasten the mounting bolts, then remove the compressor.
  10.  
  11. Installation is the reverse of the removal procedure. Tighten the compressor mounting bolts to 17-26 ft. lbs. (24-36 Nm).
  12.  
  13. Charge the A/C system, as outlined in this section.
  14.  

1.8L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Discharge the A/C system, as outlined in this section.
  4.  
  5. Remove the belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Disconnect the magnetic clutch connector.
  8.  
  9. Detach the high and low pressure hoses.
  10.  
  11. Remove the compressor mounting bolts and the compressor.
  12.  
  13. Installation is the reverse of the removal procedure. Note the following tightening specifications:
    1. Compressor mounting bolts: 18-23 ft. lbs. (24-31 Nm).
    2.  
    3. Inlet and outlet bolts: 18-23 ft. lbs. (24-31 Nm).
    4.  

  14.  
  15. Charge the A/C system, as outlined in this section.

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    Fig. Compressor mounting-1.8L engine

  16.  

2.0L Engine
  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.  
  3. Disconnect the negative battery cable.
  4.  
  5. Recover the refrigerant with a recovery/charging station.
  6.  
  7. Loosen the drive belt.
  8.  
  9. Remove the bolts, then disconnect the suction line (A) and discharge (B) line from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

    Click image to see an enlarged view

    Fig. Remove the bolts, then disconnect the suction line (A) and discharge (B) line from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination

  10.  
  11. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B). Note the lengths of the compressor bolts as you remove them, they are all different.

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



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    Fig. Note the lengths of the compressor bolts (A-D) as you remove them, they are all different. The must be installed properly and tightened in order

  12.  

To install:

  1. The compressor mounting bolts and different lengths, as follows, and must be tightened in A-B-C-D order:
    1. Bolt A: 4.96 in. (126mm) long
    2.  
    3. Bolt B: 4.65 in. (118mm) long
    4.  
    5. Bolt C: 4.02 in. (102mm) long
    6.  
    7. Bolt D: 4.02 in. (102mm) long
    8.  

  2.  
  3. Installation is the reverse of the removal procedure, noting the following:
    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 120cc (4.20 oz.) the result is the amount of oil you should drain from the new compressor(through the suction fitting)
    2.  
    3. 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
    4.  
    5. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils
    6.  
    7. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption
    8.  
    9. 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
    10.  
    11. Adjust the drive belt, as outlined in the Engine Mechanical Section.
    12.  

  4.  
  5. Charge the A/C system, as outlined in this section.
  6.  

2.4L And 2.7L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the tension pulley, then remove the drive belt.
  4.  
  5. Discharge the refrigerant with a recovery/charging station.
  6.  
  7. Disconnect the discharge and suction hoses.
  8.  
  9. Remove the mounting bolts and the compressor.

    Click image to see an enlarged view

    Fig. Compressor mounting-2.4L and 2.7L engine

  10.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the compressor mounting bolts to 14-21 ft. lbs. (20-30 Nm).
    1. Adjust the drive belt, if necessary, as outlined in the Engine Mechanical Section.
    2.  

  2.  
  3. Charge the A/C system, as outlined in this section.
  4.  

 
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