This procedure covers the replacement of the AC compressor clutch assembly on a 2015 Kia Forte with the 1.8L I4 engine, including refrigerant recovery, clutch replacement, and system recharge.

Warnings

Tools required

Parts

• AC compressor clutch assembly × 1 — Use OEM specification
• AC compressor clutch coil × 1 — Use OEM specification
• Snap ring (clutch retainer) × 1 — Use OEM specification
• AC system O-ring kit × 1 — Use OEM specification
• PAG oil (compatible with R134a) × 1 — Use manufacturer-specified viscosity

Preparation

1. Park vehicle on level ground and apply parking brake. Place wheel chocks behind rear wheels.
2. Ensure engine is completely cool before beginning work.
3. Verify you have the correct replacement clutch assembly for the Forte 1.8L compressor (Halla HCC type).
4. Connect AC recovery machine and fully recover refrigerant from the system following EPA regulations.
5. Disconnect negative battery cable and wait 3 minutes before proceeding.
6. Raise and support front of vehicle on jack stands if additional access is needed.
7. Remove engine splash shield to access compressor from below if necessary.

Procedure

1. 1

   Remove serpentine belt
   Locate the belt tensioner on the right side of the engine. Using a 14mm socket on the tensioner bolt, rotate clockwise to release tension. Slide the serpentine belt off the AC compressor pulley first, then remove from other pulleys. Note the belt routing diagram on the radiator support for reinstallation.
2. 2

   Disconnect compressor electrical connector
   Locate the clutch coil electrical connector on the front of the compressor. Press the locking tab and pull the connector straight off the coil. Move the wiring harness aside to prevent damage during clutch removal.
3. 3

   Remove clutch plate snap ring
   Using snap ring pliers, carefully remove the large snap ring that retains the clutch plate to the compressor shaft. The snap ring is located in the center of the clutch plate hub. Ensure the snap ring does not fall into the engine bay; keep track of it for inspection.
4. 4

   Remove clutch plate and pulley assembly
   With the snap ring removed, the clutch plate can now be pulled off the compressor shaft. If tight, use a clutch plate holding tool to stabilize the assembly and gently tap the hub from behind using a soft mallet. Next, remove the pulley bearing snap ring and use a pulley puller to extract the pulley assembly from the compressor nose. Inspect the pulley bearing for roughness or noise.
5. 5

   Remove clutch coil
   The electromagnetic coil is retained by a snap ring around the outer perimeter of the compressor nose. Use snap ring pliers to remove this retaining ring, then carefully slide the coil assembly off the compressor body. Note the alignment of the coil terminals for proper reinstallation.
6. 6

   Clean compressor mounting surfaces
   Using a clean, lint-free cloth, thoroughly clean the compressor shaft, nose, and all mounting surfaces. Remove any oil residue, metal shavings, or debris. Inspect the compressor shaft for scoring or damage. Check shaft end play (should be minimal) by attempting to move the shaft in and out.
7. 7

   Install new clutch coil
   Slide the new electromagnetic coil onto the compressor nose, ensuring proper alignment of the coil terminals with the connector location. Verify the coil seats fully against the compressor body. Install the new outer snap ring, ensuring it is fully seated in its groove with no gaps.
8. 8

   Install pulley and bearing assembly
   If replacing the pulley bearing, press the new bearing into the pulley housing using appropriate bearing installation tools. Apply a small amount of clean PAG oil to the compressor nose, then carefully slide the pulley assembly onto the compressor. Install the pulley retaining snap ring and verify it is fully seated. The pulley should rotate freely without binding.
9. 9

   Install clutch plate
   Slide the new clutch plate onto the compressor shaft, ensuring the friction surface faces outward toward the pulley. The clutch plate hub should slide on smoothly; if resistance is felt, do not force it. Install the new hub retaining snap ring, ensuring it seats completely in the shaft groove.
10. 10

    Verify clutch air gap
    Using a feeler gauge, measure the air gap between the clutch plate and pulley face at three points around the circumference. The gap should be 0.4-0.6mm (0.016-0.024 inches). If the gap is incorrect, verify all components are properly seated and snap rings are fully installed. An incorrect air gap will cause clutch slippage or failure to engage.
11. 11

    Reconnect electrical connector
    Reconnect the clutch coil electrical connector, ensuring it clicks into place and is fully seated. Gently tug on the connector to verify it is locked.
12. 12

    Reinstall serpentine belt
    Route the serpentine belt according to the diagram, leaving the tensioner pulley for last. Rotate the tensioner clockwise and slip the belt onto the tensioner pulley. Release the tensioner slowly and verify the belt is properly seated on all pulleys with correct rib alignment.
13. 13

    Test clutch operation
    Reconnect the negative battery cable. Without starting the engine, turn the ignition to ON and activate the AC system. You should hear an audible click as the clutch engages, and the clutch plate should pull tight against the pulley. If no engagement occurs, check electrical connections and verify battery voltage at the coil connector (should be approximately 12V when AC is requested).
14. 14

    Evacuate and recharge AC system
    Connect the AC recovery/recharge machine to the service ports. Evacuate the system for a minimum of 30 minutes to remove all air and moisture. Perform a vacuum hold test for 15 minutes; vacuum should hold steady indicating no leaks. Add the specified amount of PAG oil if any was lost during service (typically 20-30ml for clutch replacement). Recharge the system with the correct amount of R134a refrigerant per the underhood specifications label.

Reassembly

1. Reinstall engine splash shield if removed, ensuring all clips and fasteners are secure.
2. Lower vehicle from jack stands and remove wheel chocks.
3. Verify all tools and parts have been removed from the engine compartment.

Verification

• Start the engine and allow it to idle. Turn on the AC system and verify the clutch engages smoothly without abnormal noise, vibration, or squealing.
• Check that cold air is being produced at the cabin vents within 2-3 minutes of operation.
• Verify the clutch cycles on and off normally as the system maintains temperature.
• Inspect all AC line fittings and service ports for signs of refrigerant leakage using a refrigerant leak detector.
• Monitor AC system pressures with manifold gauges to ensure they are within normal operating range (low side: 25-35 PSI, high side: 200-250 PSI at idle with ambient temp 75-85°F).
• Test drive the vehicle and verify AC performance under load and that the compressor clutch functions properly during normal driving conditions.

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