KIA CARNIVAL 2007 Workshop Manual

volume, Subtract the volume of drained oil from 120cc(4.20 oz.) the result is the amount of oil you should drain
from the new compressor (through the suction fitting).
b. 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.
c. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other
refrigerant oils.
d. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
e. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint,
wash it off immediately.
f. Adjust the drive belt (Refer to HA - 14)
g. Charge the system and test its performance. (Refer to HA - 9)
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.
3.Measure the clearance between the pulley (B) and the disc & hub assembly (A) all the way around. If the
clearance is not within specified limits, remove the disc & hub assembly and add or remove shim (gap washer) as
needed to increase or decrease clearance.
Clearance: 0.45 ± 0.1mm (0.018 ± 0.004 in.)
The shims (gap washers) are available in seven thicknesses: 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm
and 1.3mm.

4.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.
DISASSEMBLY
1.Remove the center bolt (A) while holding the disc & hub assembly with a commercially available disc & hub
assembly bolt remover; Special tool number 09977 - 29000.
TORQUE: 10~15N.m (1.02~1.53kgf.m, 7.37~11lbf.ft)
2.Remove the disc & hub assembly (A) and shim (gap washer) (B), taking care not to lose the shims. If the clutch
needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the disc &
hub assembly, and recheck its clearance (Refer to HA - 19).
3.If you removal the field coil, remove retainer ring (A) with retainer ring pliers.
a.Be careful not to damage the pulley (B) and compressor during removal/installation.
b. Once retainer ring (A) is removed, replace it with a new one.

4.Remove the screw (A) from the field coil ground terminal. Remove the retainer ring (B) and then remove the field
coil (C) from the shaft with a puller. Be careful not to damage the coil and compressor.
5.Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
a. Clean the pulley and compressor sliding surfaces with non- petroleum solvent.
b. Install new retainer rings, and make sure they are fully seated in the groove.
c. Make sure that the pulley turns smoothly after its reassembled.

Compressor oil

2007 > 2.7L V6 GASOLINE >
INSPECTION
Oil Specification
1. The HFC- 134a system requires synthetic (PAG) compressor oil whereas the R- 12 system requires mineral
compressor oil. The two oils must never be mixed.
2. Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of
compressor.
Handling of Oil
1.The oil should be free from moisture, dust, metal powder, etc.
2. Do not mix with other oil.
3. The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC - 134a
Compressor Oil absorbs moisture very easily.)
4. The compressor oil must be stored in steel containers, not in plastic containers.
Compressor oil check
The oil used to lubricate the compressor is circulating with the refrigerant.
Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the
original amount of oil.
Oil total volume in system:
120±10cc (4.05±0.34 fl.oz)
Oil Return Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of
oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return
operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to "ON" and set the blower motor control knob at its highest position.
3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply the following amount of oil to the component parts to be installed.
Component parts to be installed Amount of Oil
Evaporator 50 cc (1.70 fl.oz)
Condenser 30 cc (1.02 fl.oz)
Receiver/dryer 30 cc (1.02 fl.oz)
Refrigerant line (One piece) 10 cc (0.34 fl.oz)
For compressor replacement, subtract the volume of oil drained from the removed compressor from the specified
volume, and drain the calculated volume of oil from the new compressor:
The specified volume - volume of removed compressor = volume to drain from the new compressor.
Even if no oil is drained from the removed compressor, don’t drain more than 50cc from new compressor.

Condenser

2007 > 2.7L V6 GASOLINE >
COMPONENT LOCATION

2007 > 2.7L V6 GASOLINE >
INSPECTION
1.Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with
compressed air. If bent, gently bend them using a screwdriver or pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.
REPLACEMENT
CONDENSER ASSEMBLY
1. Recover the refrigerant with a recovery/ recycling/ charging station (Refer to HA - 8).
2. Disconnect the negative ( - ) battery terminal.
3. Remove the radiator. (Refer to EM group)
4. Remove 2 bolts, and then remove the condenser (A) by lifting it up. Be careful not to damage the radiator and
condenser fins when removing the condenser.
5.Install in the reverse order of removal, and note these items :
a. If you're installing a new condenser, add refrigerant oil ND- OIL8.
b. 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.
c. Be careful not to damage the radiator and condenser fins when installing the condenser.
d. Be sure to install the lower mount cushions of condenser securely into the holes.
e. Charge the system, and test its performance. (Refer to HA - 9)
DESICCANT
1.Remove the condenser, and then remove the bottom cap (B) with L wrench (A) from the condenser.
TORQUE: 20~25N.m (2.0~2.5kgf•m, 14.5~18.2lb - ft)

2.Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged
bottom cap filter.
3.Apply air conditioning compressor oil along the O - rings and threads of the new bottom cap.
4. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed
to air for use.
5. Install the new bottom cap to the condenser.
a.Always replace the desiccant and bottom cap at the same time.
b. 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.
c. Be careful not to damage the radiator and condenser fins when installing the condenser.
d. Be sure to install the lower mount cushions of condenser securely into the holes.
e. Charge the system, and test its performance. (Refer to HA - 10)

Refrigerant Line