Model: Passenger Cars(PA)

Group: Heating, Ventilation and Air Conditioning(71)

Number: KT2007081504

Date: Friday, August 17, 2007

Area: N. America

Subject:
A/C compressor Disc & Hub/Pulley/Field Coil Assembly Inspection and Replacement
Procedure (Climate - 012)

Description

This service bulletin provides information regarding A/C Compressor Disc & Hub / Pulley /
Field Coil Assembly inspection an replacement on all current Kia models. During routine
diagnostic procedures to isolate air conditioning compressor faults such as open field coil
circuits and noises related to the disc and hub assembly, previous repairs required air
conditioning compressor replacement. Kia has made the Disc & Hub / Pulley / Field Coil
available as serviceable items. No other repair or service should be made to the air
conditioning compressor assembly outside of these replacement/serviceable items.

This TSB describes both Halla and Doowon compressors, including fixed and variable
displacement. Inspection/replacement procedures of the serviceable items are similar unless
otherwise noted.

Inspection Procedure: Field Coil Diagnosis (A/C Inoperative)

1. Start Engine. Turn the Air Conditioning (HVAC) to the "On" position.
2. Verify engagement of the compressor clutch, if the clutch is operational monitor the
cycling of the compressor clutch and road test for any intermittent conditions. If the
compressor clutch is not engaged, verify battery voltage to the field coil circuit.
3. If battery voltage is present to the compressor clutch circuit, check the field coil resistance.
4. If battery voltage is not present, check the A/C fuse.
5. If you suspect the field coil circuit has an open circuit, check the resistance between the
field coil and compressor housing. Resistance specification at 70°F: HALLA
Manufacturer Specification: 3 - 4 ohms / DOOWON Manufacturer Specification: 2.8 - 3.2
ohms. If the resistance is less / more than the specification, replace the field coil assembly
following the service procedure in this bulletin.

Inspection Procedure: Disc & Hub / Pulley Diagnosis (Abnormal Noises)

1. With the Engine "Off", visually inspect the disc and rubber insulator for abnormal signs of
heat or distortion of the rubber insulator on the disc & hub. Determine root cause of
abnormal signs of heat and or disc & hub distortion, and repair. If the disc & hub are
visually ok, continue on to functional test in steps # 2 - 5.
2. Start Engine. Turn the Air Conditioning (HVAC) to the "On" position.
3. Verify engagement of the compressor disc & hub, monitor the cycling of the compressor
clutch for abnormal noises / knocking and vibrations during disc & hub engagement. If
abnormal noises and vibrations are suspected in the disc & hub assembly, proceed to step
# 4.
4. Allow the A/C to cycle for a period of ten (10) minutes and examine the front of the A/C
disc & hub for abnormal concentric disc & hub rotations after A/C clutch engagement.
After the A/C has cycled off, visually inspect for abnormal rubbing or engagement of the
disc & hub. If you suspect that the disc & hub is worn, remove the disc & hub and inspect
for abnormal wear or slipping conditions / face wear and replace if necessary following
the service procedures in this bulletin.

Parts Information
CASUAL PARTS INFORMATION

Service Procedure
NOTICE: Procedure describes disassemble/reassembly of all 3 serviceable components,
however only components properly diagnosed as inoperative should be replaced. Refer to
Warranty Information section of this TSB to determine whether the repair can be done "On-
car" or if compressor removal and replacement is required.

Constant Capacity Compressor / Variable Capacity Compressor

1. If necessary, remove and recover the A/C refrigerant with an appropriate R-134 recovery
machine. Cover all compressor inlets/outlets and reduce any compressor oil loss.
2. Remove the compressor assembly from the vehicle.
3. Using special service tool # 09977-29000, remove the disc & hub bolt. Refer to step 12 for
bolt torque.
4. Remove the spacer shim, located between the disc & hub and compressor shaft, if
equipped.
NOTICE: Do not displace the shim, this is a select fit item and will be reused during
assembly.
5. Remove the pulley assembly retainer snap ring.

6. Remove the pulley assembly. Remove the field coil snap ring if equipped.

7. Unfasten the ground bolt for the field coil, and then remove the field coil by using a puller.
8. When installing the new field coil on the compressor assembly, be sure to align the field
coil groove and compressor housing mating mark, install the field coil snap ring, if
equipped.

9. Variable compressor field coil alignment area.

10. Ensure that during the installation of the field coil and ground bolt, the field coil is seated
completely around the circumference of the compressor housing.
11. Install the new pulley assembly and the pulley retainer snap ring.

NOTICE: during installation of retainer snap ring on DOOWON manufactured Compressors,

there is a specific orientation of the snap ring to the pulley assembly. Insure that the
beveled/sloped side of the snap ring is installed in the "UP" position.
12. Reinstall the spacer shim and disc & hub to the compressor using a new bolt. If new bolt
is not available, re-use old bolt after applying Loctite # 242 and tighten:

HALLA compressor: torque to 7.2-10.8 lbs-ft

DOOWON compressor: torque to 11-15. lbs-ft

13. Reinstall the A/C compressor and recharge the refrigerant as outlined in the service
 manual.
14. Verify proper operation of HVAC system.

WARRANTY INFORMATION