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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2019 Kia Soul EV. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • 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.
CAUTION:
  • Put on gloves to protect your hands.
NOTE:
  • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.
  • Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
  • Take care not to bend or scratch the trim and panels.
  1. Recover the refrigerant with a recovery/recycling/charging station.
    CAUTION:
    • Do not use the same A/C recovery/charging station as conventional belt-driven compressors.
    • Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
    • 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.
  2. Disconnect the negative (-) battery terminal.
  3. Shut off the high voltage circuit. (Refer to EV Battery System - "HIGH VOLTAGE SHUT-OFF PROCEDURE ")
  4. Remove the front bumper cover.

    (Refer to Body - "FRONT BUMPER COVER ")

  5. Remove the ambient temperature sensor.

    (Refer to Heating, Ventilation, Air Conditioning - "AMBIENT TEMPERATURE SENSOR ")

  6. Remove the refrigerant temperature sensor #1.

    (Refer to Heating, Ventilation, Air Conditioning - "REFRIGERANT TEMPERATURE SENSOR #1 ")

  7. Separate the refrigerant line (A) after loosening the mounting nuts.
    G11938390Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Cap the open fittings immediately to keep moisture or dirt out of the system.
  8. Pull out the side air guides (A) after pushing locker hook in the direction of the arrow.
    G11938391Courtesy of KIA MOTORS AMERICA, INC.
  9. Separate the exterior condenser (B) from the radiator after loosening bolts (A).
    G12822825Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the exterior condenser (A) in the direction of the arrow. Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
    G12822826Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION:
    • Do not use the same A/C recovery/charging station as conventional belt-driven compressors.
    • 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.
    • 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.
    • If you're installing a new condenser, add refrigerant oil (POE OIL).
    • 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.
    • Be careful not to damage the radiator and condenser fins when installing the condenser.
    • Be sure to install the lower mount cushions of condenser securely into the holes.
    • Charge the system, and test its performance.
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