Kia Rio: Air Conditioning System / Compressor

Kia Rio 2017-2020 YB Service Manual / Heating,Ventilation, Air Conditioning / Air Conditioning System / Compressor

Description and operation

Description

The compressor is the power unit of the A/C system.

It is located on the side of engine block and driven by a V-belt of engine.

The compressor changes the low pressure and low temperature refrigerant gas into the high pressure and high temperature refrigerant gas.

Variable Swash Plate Compressor

The compressor has a swash plate that rotates to reciprocate pistons, which compress refrigerant.

The variable swash plate compressor controls the swash plate angle to change the refrigerant displacement. It achieves precise cooling capability control in accordance with vehicle interior and driving conditions.

The internally controlled variable swash plate compressor changes the swash plate angle by a MCV (Mechanical Control Valve) in accordance with fluctuation of a suction pressure.

The externally controlled variable swash plate compressor changes the swash plate angle by an ECV (Electric Control Valve) in accordance with an electrical signal from the heater & A/C control unit.

This enables stable temperature control and improved driving feeling.

ECV control diagram

Components and components location

Components

Compressor

Repair procedures

Removal

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.	Remove the front tire [RH]. (Refer to Suspension System - "Wheel")

5.	Remove the front wheel guard [RH].

6.	Loosen the drive belt. D 1.4 TCI-U2(Refer to Engine Mechanical System - "Drive Belt") G 1.0 T-GDI-KAPPA(Refer to Engine Mechanical System - "Drive Belt") G 1.2 MPI-KAPPA(Refer to Engine Mechanical System - "Drive Belt") G 1.4 MPI-KAPPA(Refer to Engine Mechanical System - "Drive Belt")

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.

8.	Disconnect the compressor switch connector (A).

9.	Remove the compressor by loosening the mounting bolts.

Installation

Make sure of the length of compressor mounting bolts, and then tighten it with the specified tightening order.

Tightening torque :

21.6 - 32.4 N.m (2.04 - 3.36 kgf.m, 14.8 - 24.3 lb-ft)

Installation is 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 compressor oil capacity (120 cc). 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.

Inspection

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.	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.

External Control Valve Compressor Inspection (GDS)

Compressor type: Fixed type compressor, External control valve, Internal control valve.

In cases of fixed type and internal control valve, it is possible to inspect compressor's operation with clutch noise.

When it comes to External control valve, however, it cannot be checked in this way bacause it doesn't have a clutch.

So, ECV should be inspected with GDS as below.

1.	Connect GDS to the vehicle and select 'Aircon Compressor Test(ECV type)' [ECV1]

2.	Make the vehicle ready as the GDS instruction on the monitor. (Turn off A/C 'switch' only) [ECV2] [ECV3]

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

[ECV4]

Start inspection

[ECV5]

[ECV6]

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

Relife valve will be operated if a condenser fan doesn't work because of overpressure in the compressor. It helps the airconditiong system to relieve by releasing refrigerant and oil. (Closed if relieved)

※ Refill refrigerant and oil after operation of Relife valve

※ Noise occurred when Relife vlave is in operation

5.	Check the result of inspection. [ECV7] [ECV8]

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

7.	Inspect ECV again from the first step.

Disassembly

1.	Remove the RH front tire. (Refer to Suspension System - Wheel")

2.	Remove the front wheel guard [RH]. (Refer to Body - "Front Wheel Guard")

3.	Loosen the drive belt. D 1.4 TCI-U2(Refer to Engine Mechanical System - "Drive Belt") G 1.0 T-GDI-KAPPA(Refer to Engine Mechanical System - "Drive Belt") G 1.2 MPI-KAPPA(Refer to Engine Mechanical System - "Drive Belt") G 1.4 MPI-KAPPA(Refer to Engine Mechanical System - "Drive Belt")

Remove the center bolt (A) and the hub bolts (B) while holding the pulley with a disc & hub assembly bolt remover (0977-3R000).

Tightening torque :

15 - 21 N·m (1.5 - 2.1 kgf·m, 11.1 - 15.5 lb·ft)

5.	Remove the hub assembly (A) and shim (gap washer) (B), taking care not to lose the shim.

Remove the pulley (B) after removing the snap ring (A) with snap ring pliers.

•	Be careful not to damage the pulley and compressor during disassembly/reassembly.

•	Once snap ring is removed, replace it with a new one.

Reassembly is the reverse order of disassembly.

•	Clean the pulley and compressor sliding surfaces with non-petroleum solvent.

•	Install new snap ring, and make sure they are fully seated in the groove.

•	Make sure that the pulley turns smoothly after reassembly.

Refrigerant line

Repair procedures Replacement 1. Discharge refrigerant from refrigeration system. 2. Replace faulty tube or hose. ...

Condenser

Repair procedures 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 ...

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