This procedure adds the correct amount of PAG oil to the AC compressor to maintain proper lubrication after component replacement or system service.

Warnings

Tools required

Parts

• PAG 46 compressor oil × 1 — Use Hyundai/Kia approved PAG 46 oil
• AC system O-rings (suction and discharge) × 1 — OEM AC line O-ring kit

Fluids

• PAG 46 AC Compressor Oil — 0.25 qt

Preparation

1. Verify AC system has been properly recovered using certified recovery equipment and is at 0 PSI
2. Ensure engine is cool to the touch
3. Park vehicle on level surface and engage parking brake
4. Disconnect negative battery terminal and wait 3 minutes
5. Locate AC compressor on passenger side of engine bay, driven by serpentine belt
6. Verify you have correct PAG 46 oil specification for your refrigerant type (check underhood label)

Procedure

1. 1

   Access AC compressor discharge and suction lines
   Remove the plastic engine cover if equipped by pulling upward on clip points. Locate the AC compressor on the lower right side of the engine. Identify the discharge line (smaller diameter, high pressure) and suction line (larger diameter, low pressure) connected to the compressor rear.
2. 2

   Disconnect AC line fittings from compressor
   Using a 10mm or 12mm socket depending on fitting type, loosen and remove the bolts securing both AC line fittings to the compressor. Carefully separate the lines from the compressor. Immediately cap all open ports with clean plugs to prevent moisture and contamination entry. Remove and discard old O-rings from the line fittings.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
3. 3

   Drain existing oil from compressor
   With AC lines disconnected, slowly rotate the compressor clutch by hand 10-15 revolutions to distribute internal oil. Remove the compressor oil drain plug (if equipped) or carefully tilt the compressor to drain oil from the suction port into a clean graduated container. Measure and record the amount of oil removed. If no oil drains, compressor may be empty or seized.
4. 4

   Determine correct oil charge amount
   For this application, total system capacity is approximately 5-6 oz (150-180ml) of PAG 46 oil. If only adding oil without component replacement, add 2 oz (60ml). If compressor was replaced, add the same amount that was drained from old compressor, or 4 oz (120ml) if old compressor was empty. Consult service history to determine if other components were replaced that retained oil.
5. 5

   Inject measured oil into compressor
   Using an AC oil injector tool, draw the measured amount of fresh PAG 46 oil into the injector. Insert the injector nozzle into the compressor suction port (larger port). Slowly inject the oil while rotating the compressor clutch by hand to distribute oil internally. Rotate clutch 10 additional revolutions after oil injection is complete to ensure proper distribution throughout compressor.
6. 6

   Install new O-rings on AC line fittings
   Lightly coat new O-rings with fresh PAG oil and install them into the grooves on both AC line fittings. Ensure O-rings are properly seated and not twisted. Wipe fitting surfaces on compressor ports clean with lint-free cloth.
7. 7

   Reconnect AC lines to compressor
   Remove caps from compressor ports. Align AC line fittings with compressor ports, ensuring O-rings remain in place. Hand-thread the retaining bolts, then torque to specification using a torque wrench. Do not over-tighten as this can damage O-rings and cause leaks.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
8. 8

   Reconnect battery and prepare for evacuation
   Reconnect the negative battery terminal. Reinstall engine cover if removed. Connect AC manifold gauges to the service ports (low side on larger suction line, high side on smaller discharge line). Ensure all gauge valves are closed.
9. 9

   Evacuate and recharge AC system
   Connect vacuum pump to center port of manifold gauge set. Open both low and high side valves. Run vacuum pump for minimum 45 minutes to achieve 29+ inches of mercury vacuum. Close both valves and monitor for 15 minutes - vacuum should hold steady indicating no leaks. Recharge system with proper amount of R-134a or R-1234yf refrigerant per underhood specification label (typically 18-22 oz).

Reassembly

1. Ensure all AC line connections are tight and properly torqued
2. Verify engine cover is properly reinstalled with all clips engaged
3. Remove manifold gauges from service ports and replace protective caps

Verification

• Start engine and turn AC to maximum cold with blower on high
• Allow system to run for 5 minutes and verify cold air output from vents (38-42°F typical)
• Check compressor clutch engages and disengages normally without unusual noise
• Verify low side pressure is 25-35 PSI and high side is 180-250 PSI at idle with 80°F ambient temperature
• Inspect all AC line connections for signs of oil leakage
• Use electronic leak detector around all fittings to confirm no refrigerant leaks
• Listen for abnormal compressor noise that could indicate insufficient oil or bearing damage

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