Kia Carnival Forte Rio Sportage Sorent Air Conditioning Compressor

1. Safety & Preparation

• Park the vehicle on a flat surface, engage the parking brake, and disconnect the battery negative electrode (-).
• Wear safety gloves and goggles. Use a certified refrigerant recovery machine to evacuate the system before disassembly (required by law in most regions).

2. Remove the Old Compressor

• Disconnect Components:
  • Detach the electrical connector from the compressor clutch.
  • Remove the drive belt using a belt tensioner tool.
  • Disconnect the high-pressure and low-pressure refrigerant lines (cap/open ends immediately to prevent debris/moisture ingress).
• Unbolt the Compressor:
  • Remove mounting bolts securing the compressor to the engine bracket (verify torque specs for your model/year).
  • If seized, use penetrating oil to loosen bolts.

3. Prepare the New Compressor

• Drain Oil:
  • Drain and measure oil from the old compressor. Subtract this volume from the manufacturer’s recommended oil capacity (e.g., 120cc for Rio/Forte) and drain the same amount from the new compressor via the suction port.
• Replace O-Rings:
  • Install new R-134a-compatible O-rings on all refrigerant line fittings. Lubricate them with refrigerant oil to prevent damage during installation.

4. Install the New Compressor

• Model-Specific Notes:
  • CARNIVAL: Ensure the compressor aligns with the engine bracket (some models may require additional clearance checks).
  • Sportage: For SL models, remove undercovers or wheel wells for access.
  • Sorento: Verify mounting bolt lengths and torque specs (e.g., 19.6–33.3 N·m for Gamma/Nu engines).
• Secure the compressor with bolts and torque to 22–33 N·m (14.8–24.3 lb-ft) (verify for your model/year).
• Reconnect refrigerant lines and electrical connector.

5. System Evacuation & Charging

• Evacuate:
  • Use a vacuum pump to evacuate the system for at least 30 minutes to remove moisture/air.
• Charge with Refrigerant:
  • Add the specified oil amount and refrigerant (R-134a or R-1234yf—check your vehicle’s label).
  • Total refrigerant charge: 550 ±25g (19.4 oz) for most models.

6. Test & 

• Start the engine, activate AC, and check for cold airflow.
• Use an electronic leak detector to inspect all connections. Tighten loose fittings to 15–25 N·m (11–18 lb-ft) if leaks are detected.