Air Conditioning Refrigerant / Compressor
Repair Procedures
Refrigerant System Service Basics (R-134a)
Refrigerant Recovery
Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system.
In case of accidental discharge of the system, ventilate the work area before resuming work.
Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Connect R-134a Refrigerant Recovery/Recycling/Charging Station
Recovery/recycling/recharging system to the high-pressure service port (B) and low-pressure service port (A) as shown, in accordance with the equipment manufacturer's instructions.
Measure the amount of refrigerant oil removed from the air conditioning system after the recovery process is complete. Be sure to add the same amount of new refrigerant oil back into the air conditioning system before charging.
System Evacuation
Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system.
In case of accidental discharge of the system, ventilate the work area before resuming work.
Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
When the air conditioning system has been opened to the atmosphere, for example during installation or repair, it must be evacuated using the R-134a recovery/recycling/charging station. (If the system has been open for several days, the receiver/drier must be replaced and the system evacuated for several hours.)
Connect R-134a Refrigerant Recovery/Recycling/Charging Station
Connect the recovery/recycling/charging station to the high-pressure service port and the low-pressure service port as shown, following the equipment manufacturer's instructions.
If the low pressure does not reach 93.3 kPa (700 mmHg, 27.6 inHg) after 10 minutes, there is probably a leak in the system. Partially charge the system and check it for leaks (refer to Refrigerant Leak Test).
Remove the low-pressure valve from the low-pressure service port.
System Charging
Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system.
In case of accidental discharge of the system, ventilate the work area before resuming work.
Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Connect R-134a Refrigerant Recovery/Recycling/Charging Station
Connect the recovery/recycling/charging station to the high-pressure service port as shown, following the equipment manufacturer's instructions.
Add the same amount of new refrigerant oil to the system as was removed during recovery. Use only the specified refrigerant oil. Charge the system with 600 ± 25 g (21.2 ± 0.88 oz) of R-134a refrigerant. Do not overcharge the system, or the compressor will be damaged.
Refrigerant Leak Test
Always perform a leak test using an electronic leak detector whenever a refrigerant leak is suspected, and after service operations that involve disassembling or loosening or connecting fittings.
If a refrigerant leak is detected, perform the following steps:
Check the torque at the connection fittings and, if it is too loose, tighten to the specified torque. Check for refrigerant leakage using a leak detector (A).
If the leak continues even after tightening the fitting, drain the refrigerant from the system, disconnect the fittings, and inspect their seating surfaces for damage. Always replace them, even if the damage is minor.
Check the compressor oil and add oil if necessary.
Charge the system and recheck for leaks. If no leaks are found, evacuate and recharge the system again.
Refrigerant System Service Basics (R-1234yf)
Refrigerant Identification
Do not mix HFO-1234yf (R-1234yf) in the vehicle with other refrigerants, such as R-12, R-134a, etc.
Use only service equipment that is UL listed and certified to meet SAE standards for recovery and recycling of R-1234yf from the air conditioning system. Do not use service equipment for other refrigerants, such as R-12, R-134a, etc.
Check which 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 should be in the air conditioning system, and possible problems resulting from accidental or intentional mixing of refrigerants.
It is recommended to use a SAE certified refrigerant identifier to prevent incorrect recovery and, as a result, further spread of contaminated refrigerant, which can potentially damage other air conditioning systems and service equipment. Contaminated refrigerant (a mixture of more than one refrigerant or non-system refrigerant) in recovery/recycling equipment may lead to potential contamination of more refrigerant.
Some types of electronic leak detectors (heated diode or corona discharge), as well as motors, switches and controls on recovery and recycling machines, can produce sparks that may serve as ignition sources in the presence of refrigerants classified by ASHRAE as flammable (A2 or A3), Standard 34-2006.
Mixing refrigerants in the air conditioning system may result in higher than expected system pressure, damage to the system and components, diagnostic trouble codes, and/or other potential hazards to people and the environment.
In the event of mixing with another refrigerant, recover the contaminated refrigerant from the air conditioning system and dispose of it in accordance with all applicable national, regional or local regulations. Flush the interior of the air conditioning system with special flushing agent and charge with new refrigerant.
Refrigerant Recovery
Use only service equipment that is UL listed and certified to meet SAE standards for removal of HFO-1234yf (R-1234yf) from the air conditioning system.
In case of accidental discharge of the system, ventilate the work area before resuming work.
Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Connect R-1234yf refrigerant
Recovery/recycling/recharging system to the high-pressure service port (B) and low-pressure service port (A) as shown, in accordance with the equipment manufacturer's instructions.
Measure the amount of refrigerant oil removed from the air conditioning system after the recovery process is complete. Be sure to add the same amount of new refrigerant oil back into the air conditioning system before charging.
System Evacuation
Use only service equipment that is UL listed and certified to meet SAE standards for removal of HFO-1234yf (R-1234yf) from the air conditioning system.
In case of accidental discharge of the system, ventilate the work area before resuming work.
Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
When the air conditioning system has been opened to the atmosphere, for example during installation or repair, it must be evacuated using R-1234yf refrigerant recovery/recycling/charging equipment. (If the system has been open for several days, the receiver/drier should be replaced and the system evacuated for several hours.)
Connect R-1234yf refrigerant
Connect the recovery/recycling/charging station to the high-pressure service port and the low-pressure service port as shown, following the equipment manufacturer's instructions.
If the low pressure does not exceed 87.7 kPa (658 mmHg, 25.9 inHg) after 5 minutes, there is probably a leak in the system. Partially charge the system and check for leaks (refer to "Refrigerant Leak Check").
Remove the low-pressure valve from the low-pressure service port.
System Charging
Use only service equipment that is UL listed and certified to meet SAE standards for removal of HFO-1234yf (R-1234yf) from the air conditioning system.
In case of accidental discharge of the system, ventilate the work area before resuming work.
Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Connect R-1234yf refrigerant
Connect the recovery/recycling/charging station to the high-pressure service port as shown, following the equipment manufacturer's instructions.
Add the same amount of new refrigerant oil to the system as was removed during recovery. Use only the specified refrigerant oil. Charge the system with 520 ± 25 g (18.3 ± 0.88 oz) of R-1234yf refrigerant. Do not overcharge the system, or the compressor will be damaged.
Refrigerant Leak Test
Always perform a leak test using an electronic leak detector whenever a refrigerant leak is suspected, and after service operations that involve disassembling or loosening or connecting fittings.
If a refrigerant leak is detected, perform the following steps:
Check the torque at the connection fittings and, if it is too loose, tighten to the specified torque. Check for refrigerant leakage using a leak detector (A).
If the leak continues even after tightening the fitting, drain the refrigerant from the system, disconnect the fittings, and inspect their seating surfaces for damage. Always replace them, even if the damage is minor.
Check the compressor oil and add oil if necessary.
Charge the system and recheck for leaks. If no leaks are found, evacuate and recharge the system again.
Test yourself
A quick Kia Optima DL3 quiz: every answer comes with an explanation and a link to the manual page.