Repair Procedures: Inspection

1. Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the clutch set.
2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag.
   Fig 1: Checking Pulley Bearing Play

   Courtesy of KIA MOTORS AMERICA, INC.
3. Check operation of the magnetic clutch. Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the compressor body. Check the magnetic clutch operating noise to determine the condition.
   • Do not spill refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately.
   • Adjust the drive belt
   • Charge the system and test its performance.

Fig 2: Compressor Connection To Battery Terminals

Courtesy of KIA MOTORS AMERICA, INC.

External Control Valve Compressor Inspection (GDS) 

Compressor type: Fixed type compressor, External control valve, Internal control valve.

In cases of fixed type and internal control valve, it is possible to inspect compressor's operation with clutch noise.

When it comes to External control valve, however, it cannot be checked in this way because it doesn't have a clutch.

So, ECV should be inspected with GDS as below.

1. Connect GDS to the vehicle and select "Aircon Compressor Test (ECV type)"

   [ECV1] 

   Fig 3: Screen Display - Aircon Compressor Test (ECV Type 1)

   Courtesy of KIA MOTORS AMERICA, INC.
2. Make the vehicle ready as the GDS instruction on the monitor. (Turn off A/C "switch" only)

   [ECV2] 

   Fig 4: Screen Display - Aircon Compressor Test (ECV Type 2)

   Courtesy of KIA MOTORS AMERICA, INC.

   [ECV3] 

   Fig 5: Screen Display - Aircon Compressor Test (ECV Type 3)

   Courtesy of KIA MOTORS AMERICA, INC.
3. Check if other DTC codes are found before inspect ECV compressor. If so, solve that problems first. If not, press "OK" button to continue.

   Information 

   Do not continue inspection if these DTC codes are found: B1241, B1242, B1672, B1685, B1686, B1687

   [ECV4] 

   Fig 6: Screen Display - Aircon Compressor Test (ECV Type 4)

   Courtesy of KIA MOTORS AMERICA, INC.
4. Start inspection

   [ECV5] 

   Fig 7: Screen Display - Aircon Compressor Test (ECV Type 5)

   Courtesy of KIA MOTORS AMERICA, INC.

   [ECV6] 

   Fig 8: Screen Display - Aircon Compressor Test (ECV Type 6)

   Courtesy of KIA MOTORS AMERICA, INC.
   CAUTION: Check if condenser fan is operating when condition is changed to "ECV running"
   CAUTION: Relief Valve will be operated if the condenser fan does not work because of over pressure in the compressor. The Relief Valve helps the air conditioning system to relieve pressure by releasing refrigerant and oil (closes valve when relived).
   * Refill refrigerant and oil after operation of Relief Valve.
   * Noise is normal when Relief Valve is in operation.
5. Check the result of inspection.

   [ECV7] 

   Fig 9: Screen Display - Aircon Compressor Test (ECV Type 7)

   Courtesy of KIA MOTORS AMERICA, INC.

   [ECV8] 

   Fig 10: Screen Display - Aircon Compressor Test (ECV Type 8)

   Courtesy of KIA MOTORS AMERICA, INC.
6. If the result shows "Check", click "Check" and follow the instruction.
   Fig 11: Screen Display - Aircon Compressor Test (ECV Type)

   Courtesy of KIA MOTORS AMERICA, INC.
7. Inspect ECV again from the first step.