Kia Soul EV: Air Conditioning System / Electric A/C compressor Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Heating,Ventilation, Air Conditioning / Air Conditioning System / Electric A/C compressor Repair procedures

Removal
   
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.
Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
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.
Disconnect the negative (-) battery terminal.
3.
Shut off the high voltage circuit.
(Refer to EV Battery system - "High Voltage Shut-off Procedure")
4.
Recover the refrigerant with a recovery/charging station.
   
If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the A/C compressor may not work.
5.
Disconnect the compressor connector (A) and high voltage connector (B) after loosening bolt.

   
Disconnect high voltage connector by pressing the locker pin (A) and pressing the lever (B).

6.
Remove the fixing clip of compressor high voltage cable (A).

7.
Remove the engine room under cover.
(Refer to Traction Motor System - "Under Cover")
8.
Remove the engine room under side cover [LH].
(Refer to Traction Motor System - "Under Cover")
9.
Remove the suction hose (A) and discharge hose (B) after loosening bolts and nuts.
[Without Heat Pump]

[With Heat Pump]

   
When separating the refrigerant line, it must cover the plug or cap for protecting the A/C system from the humidity and dust.
10.
Remove the electirc A/C compressor (A) after loosening the mounting bolts.
[Without Heat Pump]

[With Heat Pump]

Installation
1.
Make sure that the compressor mounting bolt with the correct length is screwed in. Tighten the mounting bolts to the specified tightening order.

Tightening torque :
10.0 ~ 15.0 N.m (2.04 ~ 3.36 kgf.m, 7.37 ~ 11.0 lb-ft)

2.
Install in the reverse order of removal and note the followings:
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 125±10cc. 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 PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the A/C compressor may not work.
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