Kia Rio: Heating, Ventilation, Air Conditioning / Air Conditioning System

General Safety Information and Precautions

Instructions

When Handling Refrigerant

1
Liquid refrigerant R-134a evaporates very easily. A drop on your skin may cause local frostbite. Always wear gloves when working with refrigerant.
2
It is standard practice to wear protective goggles or safety glasses and gloves to protect the hands. If refrigerant gets into the eyes, flush them immediately with clean water.
3
The R-134a container is under high pressure. Never leave it in a hot place, and make sure the storage temperature is below 52 °C.
4
Use an electronic leak detector to check the system for refrigerant leaks. Note that R-134a produces phosgene, a very toxic gas, when it contacts an open flame.
5
Use only the lubricant recommended for R-134a systems. If lubricants other than the recommended type are used, system failure may occur.
6
PAG lubricant absorbs moisture from the atmosphere very quickly, so the following precautions must be observed:
- When removing refrigerant components from the vehicle, cap the components immediately to prevent moisture from entering.
- When installing refrigerant components on the vehicle, do not remove the cap until immediately before connecting the components.
- Complete the connection of all refrigerant lines and hoses without delay to prevent moisture from entering the air conditioning system.
- Use only recommended lubricant taken from a sealed container.
7
In the event of an accidental discharge into the system, ventilate the work area before resuming service.

When replacing parts in the air conditioning system

1
Never open or loosen a connection until the system has been discharged.
2
Immediately cap or plug open component fittings to prevent moisture or dirt from entering.
3
Do not remove the sealing caps from a replacement component until it is ready for installation.
4
Always install a new O-ring before connecting an open fitting. Lubricate and seal the fitting with refrigerant oil before connecting.

When installing, connect parts

Flange with Guide Pin

Check the new O-ring for damage (use only the specified part) and lubricate it with compressor oil. Tighten the nut to the specified torque.

Handling of Tubes and Fittings

The internal parts of the refrigeration system will remain chemically stable as long as clean refrigerant free of moisture and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can disturb chemical stability and cause malfunctions or serious damage.

The following precautions must be observed

1
When the refrigerant system must be opened, prepare all the parts needed to service the system in advance so that the system is not left open longer than necessary.
2
Close or plug all lines and fittings as soon as they are opened to prevent dirt and moisture from entering.
3
All lines and components in parts storage must remain capped or sealed until they are ready for use.
4
Never attempt to bend formed lines to make them fit. Use the correct line for the system you are servicing.
5
All tools, including the refrigerant dispensing manifold, manifold gauge set and charging hoses, must be kept clean and dry.

Precautions (R-1234yf)

Caution

In case of an emergency, the following precautions must be observed: The first aider must protect themselves. Immediately remove all contaminated clothing.

Inhalation: Move to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Use oxygen as needed, provided a qualified operator is present. Call a physician.
Skin contact: If skin contact occurs, immediately flush with plenty of water. Rapid evaporation of the liquid may cause frostbite. If signs of frostbite are present, rinse (do not rub) with lukewarm water (not hot water). If water is not available, cover with a clean, soft cloth or similar covering. Call a physician. Wash contaminated clothing before reuse.
Eye contact: Immediately flush with plenty of water, including under the eyelids, for at least 15 minutes. In case of frostbite, use lukewarm water, not hot water. Call a physician.
Ingestion: An unlikely route of exposure. Since 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 a person who is unconscious. Call a physician immediately.

Caution

The following precautions must be observed when handling refrigerant:

Handle with care.
Wear personal protective equipment.
Do not breathe vapor.
Avoid contact with skin, eyes and clothing.
Make sure eyewash stations and emergency showers are located near the workstation.
Use only in well-ventilated areas.
Keep away from direct sunlight and do not expose to temperatures exceeding 50°C (122°F).
Observe all standard precautions when handling and using compressed gas cylinders.
Use only certified cylinders.
Protect cylinders from physical damage.
Do not puncture or drop cylinders, and do not expose them to open flame or excessive heat.
Do not remove the screw cap until ready for use.
Always replace the cap after use.
Empty container is hazardous.
Prevent the formation of flammable or explosive vapor-air concentrations and avoid vapor concentrations above workplace exposure limits.
Keep the product and empty container away from heat sources and ignition sources.
Do not pressurize, cut, weld, braze, solder, drill, grind or expose containers to heat or sources of ignition.
Take precautionary measures against static discharge.
Electrical equipment must be protected in accordance with the applicable standard.
Use explosion-proof equipment.
Do not use spark-producing tools.
No smoking.

Caution

Avoid breathing refrigerant vapor and lubricant mist. To remove refrigerant from the air conditioning system, use service equipment designed for recovery and recycling, certified to meet the requirements of the applicable SAE standards.
Never pressurize any mobile air conditioning system containing R-134a or R-1234yf refrigerant with shop air or any other refrigerant, such as HCFC-22 (R-22), for leak testing. Doing so may cause chemical reactions, flammability of the air/R-134a mixture at elevated pressure, system contamination, and possible structural damage to the system.
To prevent refrigerant accumulation in the event of a major refrigerant leak, open the vehicle windows and doors when charging the air conditioning system.
To prevent accidental refrigerant release and minimize safety hazards, connect any refrigerant service equipment to the vehicle only with the engine off and after the refrigerant pressure on the high-pressure side has been reduced (approximately 2-3 minutes).

When Handling Refrigerant

NOTE

Some of the practices, techniques and procedures, as well as the information, tools and equipment normally used in diagnosing and servicing R-12 and R-134a mobile air conditioning systems, differ for systems using R-1234yf.

Modifications and adjustments must be made based on the individual characteristics of each refrigerant. No technician may service or repair a mobile air conditioning system using R-1234yf without refrigerant training. Per SAE J2845, the refrigerant system must be serviced only by trained and certified technicians to ensure correct and safe operation.
Service technicians must always wear appropriate personal protective equipment when handling or servicing systems containing refrigerant.
Service personnel must read and follow the appropriate Material Safety Data Sheets (MSDS) for safety information and the correct use of personal protective equipment.

- Avoid any contact with liquid or gaseous refrigerant.

- Wear safety goggles with side shields and gloves (insulated against heat loss and impermeable to refrigerant) when working on the refrigerant circuit.

- Refrigerant contact with the skin may cause frostbite. In this case, wash the affected area with warm water. Consult a doctor immediately regarding frostbitten skin areas.
If complaints persist, seek medical attention immediately after exposure to high refrigerant concentrations. Complaint symptoms may include: rapid breathing, shortness of breath, headache, rapid pulse, dizziness.
Avoid breathing air conditioning refrigerant and oil mist or vapor. Use service equipment designed to recover the refrigerant certified to meet the requirements of the applicable SAE standards to remove refrigerant from the air conditioning system.

1
Liquid R-1234yf refrigerant evaporates very quickly. A drop on your skin may cause localized frostbite. Always wear gloves when handling refrigerant.
2
It is standard practice to wear protective goggles or safety glasses and gloves to protect the hands. If refrigerant gets into the eyes, flush them immediately with clean water.
3
The R-1234yf container is under high pressure. Never leave it in a hot place, and make sure the storage temperature is below 52 °C.
4
Use an electronic leak detector to check the system for refrigerant leaks. Be aware that R-1234yf produces phosgene, a highly toxic gas, when exposed to flame.
5
Use only the lubricant recommended for R-1234yf systems. If lubricants other than those recommended are used, system failure may occur.
6
PAG lubricant absorbs moisture from the atmosphere very quickly, so the following precautions must be observed:
- When removing refrigerant components from the vehicle, cap the components immediately to prevent moisture from entering.
- When installing refrigerant components on the vehicle, do not remove the cap until immediately before connecting the components.
- Complete the connection of all refrigerant lines and hoses without delay to prevent moisture from entering the air conditioning system.
- Use only recommended lubricant taken from a sealed container.
7
In the event of an accidental discharge into the system, ventilate the work area before resuming service.
8
Remove all dirt, grease, and debris from and around refrigerant connections before servicing and disconnecting refrigerant connections.

Description and Operation

Refrigeration Cycle

Repair Procedures

Checking Refrigerant Specifications

1
Check the refrigerant specification label inside the engine compartment.

R-134a R-1234yf

Examples
2
If the refrigerant specification label is not visible, check the diameter of the service port.

R-134a R-1234yf

High-pressure side

Low-pressure side

※ The service port diameter for the high/low pressure side depends on the refrigerant specification.

Refrigerant System Service Basics

Refrigerant Recovery

Use only UL-listed service equipment certified to SAE J2210 for recovering R-134a refrigerant from the air conditioning system.

In case of accidental discharge of the system, ventilate the work area before resuming work.

. For additional health and safety information, contact the lubricant manufacturer.

1
Connect R-134a Refrigerant Recovery/Recycling/Charging Station

Connect the recovery/recycling/charging equipment (A) to the high-pressure service port (B) and low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
2
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 UL-listed service equipment certified to SAE J2210 for recovering R-134a refrigerant from the air conditioning system.

In the event of an accidental system discharge, ventilate the work area before resuming service.

Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

1
When the air conditioning system has been opened to the atmosphere, for example during installation or repair, it must be evacuated using an R-134a recovery/recycling/charging system. (If the system has been open for several days, replace the receiver/drier and evacuate the system for several hours.)
2
Connect R-134a Refrigerant Recovery/Recycling/Charging Station

Connect the recovery/recycling/charging equipment (A) to the high-pressure service port (B) and low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
3
If the low-side 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 for leaks (refer to "Refrigerant Leak Check").
4
Remove the low-pressure valve from the low-pressure service port.

System Charging

Use only UL-listed service equipment certified to SAE J2210 for recovering R-134a refrigerant from the air conditioning system.

In the event of an accidental system discharge, ventilate the work area before resuming service.

Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

1
Connect R-134a Refrigerant Recovery/Recycling/Charging Station

Connect the recovery/recycling/charging equipment (A) to the high-pressure service port (B) as shown, following the equipment manufacturer's instructions.
2
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 450 ± 25 g (15.7 ± 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:

1
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).
2
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.
3
Check the compressor oil and add oil if necessary.
4
Charge the system and recheck for leaks. If no leaks are found, evacuate and recharge the system again.

Components and Component Location

Component Location Index

Engine Compartment

1. Receiver-Drier
2. Condenser
3. Ambient Temperature Sensor
4. Compressor
5. Drain Hose

6. Suction & Liquid Line Assembly
7. Service Port (Low Pressure)
8. Service Port (High Pressure)
9. Air Conditioner Pressure Transducer (APT)
10. Expansion Valve

Interior

1. Automatic Anti-Fog Sensor
2. Photo Sensor
3. Heater and A/C Controller (MANUAL)

4. Heater and A/C Controller (FATC)
5. Heater and Blower Fan
6. Evaporator Temperature Sensor

	R-134a	R-1234yf
High-pressure side
Low-pressure side

Air Conditioning

General Safety Information and Precautions

Instructions

Precautions (R-1234yf)

Description and Operation

Refrigeration Cycle

Repair Procedures

Checking Refrigerant Specifications

Refrigerant System Service Basics

Components and Component Location

Component Location Index

Engine Compartment

Interior

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