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Home >> Kia >> 2023 >> Sorento Plug-In Hybrid SX Prestige >> Repair and Diagnosis >> External Pages >> Different car >> Section 82 (Air Conditioning System (PHEV)) >> Electric A/C Compressor >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING: This page is about a different car, the 2024 Kia Sorento. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • When working on the high voltage system, the work should be performed by technicians who have completed the relevant training. A lack of understanding of the high voltage system can lead to serious accidents due to electric shock or short circuit.
  • When working on the high voltage system or related components, be sure to observe and be aware of the "Safety Precautions, Cautions and Warnings". If not, it may cause serious accidents due to electric shock or short circuit.
  • When working on the high voltage system, make sure to check the Personal Protective Equipment (PPE) and high voltage shut-off procedure.
  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 (-) battery terminal.

    (Refer to Engine Electrical System - "AUXILIARY BATTERY ")

  3. Recover the refrigerant with a recovery/charging station.
  4. Remove the engine room under cover.

    (Refer to Engine Mechanical System - "ENGINE ROOM UNDER COVER ")

  5. Separate the suction hose (A) and discharge hose (B) by removing the mounting bolts.

    Tightening torque: 

    19.6 - 39.2 N.m (2.0 - 4.0 kgf.m, 14.4 - 28.9 lb-ft)

    CAUTION:
    • Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
    G14958856Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the electric compressor connector (A).
    G14958857Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the screw from the wiring mounting bracket.
    G14958858Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the electric compressor assembly (A) by removing the mounting bolts.

    Tightening torque: 

    19.6 - 33.3 N.m (2.0 - 3.4 kgf.m, 14.4 - 24.5 lb-ft)

    G14958859Courtesy of KIA MOTORS AMERICA, INC.
    Fig 1: Electric Compressor Assembly Bolts Loosening Sequence
    G14958860Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the compressor high voltage connector (A) by pulling the lock pin.
    G14958861Courtesy of KIA MOTORS AMERICA, INC.
  10. The inverter/body kit is an electronic component and can be damaged by dust or humidity. It should be moved to the clean room.
    NOTE:
    • To prevent the inverter/body kit from getting contaminated, remove dust or dirt from the exterior of the compressor.
    • Do not open the package until the inverter/body kit is installed, to prevent the inverter/body kit from getting contaminated.
  11. Remove the bolt that fixes the inverter/body kit.
    NOTE:
    • Do not recycle the inverter/body kit fastening bolt.
    • Never remove unmarked bolts.
    G14958862Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the inverter kit (A) and body kit (B).
    G14958863Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: When removing the inverter/body kit, be careful not to damage, twist or bend the 3-phase power pin (B).
    G14958864Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the inverter/body kit gasket (A).
    NOTE:
    • Gaskets prohibit reuse.
    • When removing the gasket, prohibit the use of sharp tools and pay attention to damage.
    G14958865Courtesy of KIA MOTORS AMERICA, INC.
  14. Apply the thermal grease as in the following before replacing the inverter/body kit.

    Applied amount:  3 - 4 g (compressor radiator)

    NOTE:
    • When replacing the inverter/body kit, make sure to prevent static electricity and maintain a clean room (keep constant temperature and humidity: 22°C [71.6°F] - 23°C [73.4°F], 50%)
    • Make sure to use the provided thermal grease as generic grease is not allowed.
    • When replacing the inverter or body kit, it is recommended to wipe off the previously applied thermal grease and apply the provided thermal grease.
    G14958866Courtesy of KIA MOTORS AMERICA, INC.
  15. Install the new gasket and the inverter kit (A) and body kit (B) while being careful not to damage the 3-phase power pin.
    NOTE:
    • When installing the inverter/body kit, be careful not to damage, twist or bend the 3-phase power pin.
    • Recycling the inverter/body kit fastening bolt and gasket is prohibited.
    G14958867Courtesy of KIA MOTORS AMERICA, INC.
  16. Use the new fastening bolt to install the inverter kit and body kit.

    Tightening torque: 

    5.9 - 6.9 N.m (0.6 - 0.7 kgf.m, 4.3 - 5.1 lb.ft)

    NOTE:
    • When installing the inverter/body kit, be careful about PCB bending that may occur inside the inverter/body kit cased by engine vibration in the event of excessive or insufficient torque.
    • Do not recycle the inverter kit and body kit fastening bolt.
    G14958868Courtesy of KIA MOTORS AMERICA, INC.
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