Kia Optima Hybrid: Air Conditioning System / Electric A/C compressor Repair procedures

Removal
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 - High Voltage Shutoff)
3.
Recover the refrigerant with a recovery/charging station.
   
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).

Installation
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.
   
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.
Inspection
   
Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
1.
Shut off the High Voltage circuit.
(Refer to "High Voltage Shutoff Procedure" in this group)
2.
Remove the air cleaner assembly and duct.
(Refer to "Intake and Exhaust System" in EM group)
3.
Drain the coolant of the hybrid motor cooling system and remove the reservoir installed on the HPCU.
(Refer to "Hybrid Motor Cooling System" in HM group).
4.
Disconnect the coolant inlet hose (A) and outlet hose (B).
5.
Remove the HPCU protector (C).

6.
Disconnect the power cable (A) from the HPCU.
(1)
Pull the lever (B) in the direction of the arrow with the hook (C) pressed.
(2)
Press the lever (D), and then pull the power cable connector.

7.
Disconnect the motor power cable (A) and HSG power cable (B).
(1)
Disconnect the connector by rotating the lever (C) after pulling the lever (D).

8.
Disconnect the electric A/C compressor power cable (A).
(1)
Pull the lever (B) in the direction of the arrow.
(2)
Press the hook (C), and then pull the motor power cable connector.

9.
Measure the capacitors between (+) terminal and (-) terminal of the compressor connector.

Specified Value : 98? ±2%

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