Kia Optima: Heating, Ventilation and Air Conditioning / Air Conditioning System

Kia Optima DL3 2019-2020 Service and Repair Manual / Heating, Ventilation and Air Conditioning / Air Conditioning System

General safety information and caution
Instructions (R-134a)

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 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 recommended lubricant for R-134a systems. If lubricants other than the recommended one 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, cap the components immediately to prevent 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 resum of 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.

When Installing Connecting Parts

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.

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.

Instructions (R-1234yf)
  

The R-1234yf liquid refrigerant is flammable gas. The gas reduces oxygen available for breathing and causes asphyxiation in high concentrations. The victim will not realize that he/she is suffocating.

Inhalation may cause central nervous system effects and may cause drowsiness and dizziness.

Ingestion may cause gastrointestinal discomfort. It may cause skin irritation, eye irritation and respiratory tract irritation. Do not breathe vapour. Avoid contact with skin, eyes and clothing.

  

In case of emergency, the following precautions must be observed;First aider needs to protect himself. Take off all contaminated clothing immediately.

Inhalation : Move to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Use oxygen as required, provided a qualified operator is present. Call a physician.

Skin contact : After contact with skin, wash immediately with plenty of water. Rapid evaporation of the liquid may cause frostbite. If there is evidence of frostbite, bathe (do not rub) with lukewarm (not hot) water. If water is not available, cover with a clean, soft cloth or similar covering. Call a physician. Wash contaminated clothing before re-use.

Eye contact : Rinse immediately with plenty of water, also under the eyelids, for at least 15 minutes. In case of frostbite water should be lukewarm, not hot. Call a physician.

Ingestion : Unlikely route of exposure. As this product is a gas, refer to the inhalation section. Do not induce vomiting without medical advice. If conscious, drink plenty of water. Never give anything by mouth to an unconscious person. Call a physician immediately.

  

When handling the refrigerant, the following precautions must be observed;

Handle with care.

Wear personal protective equipment.

Do not breathe vapour.

Avoid contact with skin, eyes and clothing.

Ensure that eyewash stations and safety showers are close to the workstation location.

Use only in well-ventilated areas.

Protect from sunlight and do not expose to temperatures exceeding 52°C (125°F).

Follow all standard safety precautions for handling and use of compressed gas cylinders.

Use authorized cylinders only.

Protect cylinders from physical damage.

Do not puncture or drop cylinders, expose them to open flame or excessive heat.

Do not remove screw cap until immediately ready for use.

Always replace cap after use.

Container is hazardous when empty.

Prevent the creation of flammable or explosive concentrations of vapour in air and avoid vapour concentration higher than the occupational exposure limits.

Keep product and empty container away from heat and sources of ignition.

Do not pressurize, cut, weld, braze, solder, drill, grind or expose containers to heat or sources of ignition.

Take measures to prevent the build up of electrostatic charge.

Electrical equipment should be protected to the appropriate standard.

Use explosion-proof equipment.

No sparking tools should be used.

No smoking.

  

When storing the refrigerant, the following precautions must be observed;

Pressurized container. Protect from sunlight and do not expose to temperatures exceeding 52°C (125°F). Do not pierce or burn, even after use.

Keep containers tightly closed in a dry, cool and well-ventilated place.

Keep away from heat and sources of ignition.

Storage rooms must be properly ventilated.

Ensure adequate ventilation, especially in confined areas.

Protect cylinders from physical damage.

Store away from incompatible substances.

Store in original container.

  

Un-controlled release of R-1234yf refrigerant in the work area may result in high concentrations of R-1234yf that can be flammable. Servicing of R-1234yf systems shall only be done in well ventilated work areas.

When servicing, maintaining or repairing A/C systems using flammable refrigerants (mildly flammable or higher) the work place shall meet all applicable national, regional or local regulations for work place safety as related to high pressure or flammable gases.

  

Avoid breathing any refrigerant vapor and lubricant mist. To remove refrigerant from a A/C system, use service equipment designed for recovery and removal that is certified to meet the requirements of the appropriate SAE Standards.

Do not increase pressure, in any R-134a, or R-1234yf mobile A/C system with shop air or another refrigerant such as HCFC-22 (R-22) for leak checking, due to potential chemical reactions, flammability of air / R-134a at elevated pressure, contamination of the system, and possible structural damage to the system.

To prevent an accumulation of refrigerant in case of a major refrigerant leak, open vehicle windows and doors when charging an A/C system

To prevent accidental release of refrigerant and minimize safety concerns, the installation of any refrigerant service equipment to the vehicle shall only be done with the engine off and after the refrigerant high side pressure has been reduced (approximately 2 to 3 min).

  

The proper handling procedures should be followed for all refrigerants as designated by the refrigerant manufacturer’s Material Safety Data Sheet (MSDS).

Service personnel shall be aware of the high pressure relief valve location when servicing the vehicle. Service personnel shall not be under the vehicle when charging the refrigerant system due to potential sudden release of the high pressure relief valve.

When Handling Refrigerant

  

Some of the practices, techniques and procedures, as well as the information, tools and equipment which have been commonly used in mobile air conditioning system diagnosis and service of R-12 and R-134a are different for A/C systems using R-1234yf.

Modifications and adjustments have to be made based on the individual characteristics of each refrigerant. No technician may perform service or repair on a mobile air conditioning system using R-1234yf without being trained for the refrigerant being handled. Under the SAE Standard J2845 the refrigerant system should only be serviced by trained and certified technicians to insure proper and safe operation.

Service technicians should always wear proper personal protective equipment while handling / servicing systems that contain any refrigerant.

Service technicians shall read and follow the appropriate Material Safety Data Sheets (MSDS), which provide information on safety and the proper personal protective equipment to use.

- All contact with liquid or gaseous refrigerant shall be avoided.

- Goggles with side protection and gloves (insulated against heat loss and impermeable to refrigerant) shall be worn while working with the refrigerant circuit.

- Exposure of the skin to refrigerant may result in frostbite, in which case rub affected area with lukewarm water. A physician shall be consulted immediately regarding the affected skin areas.

A physician shall be consulted immediately in the event of complaints following exposure to high refrigerant concentrations. Complaint symptoms may include: increased breathing rate, breathlessness, headache, accelerated pulse, dizziness.

Avoid breathing A/C refrigerant and lubricant vapor or mist. To remove refrigerant from the A/C system, use service equipment designed for recovery of that refrigerant which is certified to meet the requirements of the appropriate SAE Standards.

1.

R-1234yf 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-1234yf container is highly pressurized. Never leave it in a hot place, and check storage temperature is below 52°C (125°F).

4.

An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-1234yf, upon coming into contact with flame, produces phosgene, a highly toxic gas.

5.

Use only recommended lubricant for R-1234yf systems. If lubricants other than the recommended one 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, cap the components immediately to prevent 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 resume of service.

8.

Clean all dirt, grease and debris from and around connection joints before servicing and disassembly of refrigerant connections.

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.

5.

The air conditioning evaporator (cooling coil) shall never be repaired or replaced with one removed from a used or salvaged vehicle and that new replacement A/C evaporators shall be certified (and labeled) as meeting SAE Standard J2842.

6.

In the case of all vehicles being serviced and identified as having a leaking evaporator, the leak shall not be repaired and the system shall only be serviced by replacing the leaking evaporator with a new evaporator meeting SAE J2842 requirements. An evaporator from a salvaged vehicle air conditioning system shall not be repaired or removed from any vehicle air conditioning system with the intention of using it again in the same or a different vehicle. However, if the evaporator assembly includes a refrigerant control device (TXV / Block valve) and is operational, re-use of the refrigerant control device is permitted.

When Installing Connecting Parts

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.

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.

6.

Carefully inspect refrigerant connections, joint seals and seal surfaces for signs of wear, deformation, contamination or damage after disassembly. Prior to disassembly, look for presence of refrigerant oil on adjacent surfaces that could be sign of a leak.

7.

Never reuse seals / O-rings, but replace with all new parts.

8.

Ensure proper alignment of male/female portions and seal so there is no misalignment and stress on the fitting connection.

Description and operation
Refrigeration Cycle

Repair procedures
Refrigerant System Service Basics (R-134a)

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.

  

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.

Be careful when connecting service equipment.

Do not breathe refrigerant or vapor.

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.

1.

Connect an R-134a refrigerant

Recovery / Recycling / Charging System to the high-pressure service port (B) and the low-pressure service port (A) 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.

  

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.

Be careful when connecting service equipment.

Do not breathe refrigerant or vapor.

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.

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 to the high-pressure service port and the low-pressure service port 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 Refrigerant Leak Test).

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.

  

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.

Be careful when connecting service equipment.

Do not breathe refrigerant or vapor.

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.

1.

Connect an R-134a refrigerant

Recovery / Recycling / Charging System to the high-pressure service port 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 600 ± 25 g (21.2 ± 0.88 oz.) of R-134a refrigerant. Do not overcharge the system the compressor will be damaged.

Refrigerant Leak Test

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.

  

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 (A).

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.

Refrigerant System Service Basics (R-1234yf)

Refrigerant Identification

Do not mix HFO-1234yf (R-1234yf) in the vehicle with other refrigerant, such as R-12, R-134a and etc.

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE standards to recover and recycle R-1234yf from the air conditioning system. Do not use service equipment for the other refrigerant, such as R-12, R-134a and etc.

Verify what refrigerant is in the system if there is concern that the system has been tampered with in any way and check the type and quantity of refrigerant that shall be in the A/C system and potential issues arising from accidental or intentional mixing of refrigerants.

Using an SAE certified refrigerant identification device is recommended to prevent improper recovery and the resulting further spread of contaminated refrigerant, which could potentially damage other A/C systems and service equipment. Contaminated refrigerant (blend of more than one refrigerant or non-system refrigerant) in recovery / recycling equipment could lead to the potential contamination of more refrigerant.

Certain types of electronic leak detection devices (heated diode or corona discharge) as well as motors, switches, and controls on recovery and recycling machines, could generate sparks that could serve as ignition sources in the presence of refrigerants classified as flammable (A2 or A3) by ASHRAE standard 34 2006.

It is possible that the mixing of refrigerants in a A/C system can result in higher-than-expected system pressures, system and component damage, diagnostic errors and/or other potential hazards to people and environment.

In case other refrigerant is mixed, recover the contaminated refrigerant in the A/C system and dispose it in accordance with all applicable national, regional or local regulations. Clean inside the A/C system using the specialized detergent and recharge new refrigerant.

Refrigerant Recovery

Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE standards to remove HFO-1234yf (R-1234yf) from the air conditioning system.

  

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.

Be careful when connecting service equipment.

Do not breathe refrigerant or vapor.

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.

1.

Connect an R-1234yf refrigerant

Recovery / Recycling / Charging System to the high-pressure service port (B) and the low-pressure service port (A) 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 standards to remove HFO-1234yf (R-1234yf) from the air conditioning system.

  

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.

Be careful when connecting service equipment.

Do not breathe refrigerant or vapor.

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.

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-1234yf 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-1234yf refrigerant

Recovery / Recycling / Charging System to the high-pressure service port and the low-pressure service port as shown, following the equipment manufacturer's instructions.

3.

If the low-pressure does not reach more than 87.7 kPa (658 mmHg, 25.9 in.Hg) in 5 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks (see "Refrigerant Leak Test").

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 standards to remove HFO-1234yf (R-1234yf) from the air conditioning system.

  

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.

Be careful when connecting service equipment.

Do not breathe refrigerant or vapor.

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.

1.

Connect an R-1234yf refrigerant

Recovery / Recycling / Charging System to the high-pressure service port 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 520 ± 25 g (18.3 ± 0.88 oz.) of R-1234yf refrigerant. Do not overcharge the system the compressor will be damaged.

Refrigerant Leak Test

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.

  

In order to use the leak detector properly, read the manual supplied by the manufacturer.

  

Use only leak detection devices certified to SAE standards for use with R-1234yf. Certain leak detection devices (heated diode or corona discharge) could serve as ignition sources in the presence of hydrocarbons or other flammable refrigerants.

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 (A).

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.

Components and components location
Component Location Index

Engine Room

1. Compressor
2. Discharge hose
3. Service port (Low pressure)
4. Service port (High pressure)
5. A/C Pressure transducer (APT)
6. Suction & Luquid tude assembly
7. Expanshion valve


[Interior]

1. Auto defogging sensor
2. Photo sensor
3. Heater & Blower unit
4. Heater & A/C Control unit
5. Exaporator temperature sensor

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