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

Warnings

Tools required

Parts

• AC Compressor × 1 — Use OEM specification for 1.8L engine
• AC line O-rings × 1 — Suction and discharge line O-rings
• Serpentine belt × 1 — Replace if worn or contaminated with oil
• PAG oil × 1 — ND-11 PAG oil for Kia AC systems

Fluids

• R-134a Refrigerant

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery cable
4. Raise front of vehicle and support securely on jack stands
5. Remove passenger side front wheel for improved access
6. Remove lower engine splash shield

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to service ports. Follow machine instructions to completely recover all refrigerant from the system. Verify system is at 0 PSI before proceeding. This step is legally required and must be completed before any AC lines are disconnected.
2. 2

   Remove serpentine belt
   Locate the belt tensioner on the passenger side of the engine. Using a serpentine belt tool or appropriate socket, rotate the tensioner clockwise to release tension. Remove the belt from all pulleys including the AC compressor pulley. Inspect belt for oil contamination or damage and replace if necessary.
3. 3

   Disconnect electrical connector
   Locate the AC compressor clutch electrical connector on the front of the compressor. Press the release tab and disconnect the connector. Move wiring harness aside to prevent damage during compressor removal.
4. 4

   Disconnect AC line fittings
   Using appropriate line wrenches, disconnect the suction line (larger diameter) and discharge line (smaller diameter) from the rear of the compressor. Be prepared for residual oil drainage. Cap all open fittings immediately to prevent moisture and debris entry. Remove and discard the old O-rings from both fittings.
   ⚠Have drain pan ready as refrigerant oil will drain from disconnected lines and compressor ports.
5. 5

   Remove compressor mounting bolts
   Locate the compressor mounting bolts. There are typically 3-4 bolts securing the compressor to the engine block bracket. Remove all mounting bolts while supporting the compressor weight. The compressor is accessible from both above and below the vehicle.
6. 6

   Remove AC compressor
   Carefully lower the compressor down and out through the passenger side wheel well opening. Tilt and maneuver as needed to clear surrounding components. Place compressor in drain pan and allow all oil to drain. Measure and record the amount of oil drained.
7. 7

   Prepare new compressor
   Check new compressor for correct part number and pulley type. Drain the shipping oil from the new compressor. Add the proper amount of fresh ND-11 PAG oil: use the same amount that was drained from the old compressor, or follow new compressor instructions if different. Rotate compressor pulley by hand 10 times to distribute oil internally.
8. 8

   Install new compressor
   Maneuver the new compressor into position through the wheel well opening. Align compressor with mounting bracket on engine block. Thread all mounting bolts by hand first to ensure proper alignment, then torque to specification in a cross-pattern.
9. 9

   Install new O-rings and connect AC lines
   Install new O-rings on both the suction and discharge line fittings. Lightly coat O-rings with fresh PAG oil. Thread fittings by hand onto compressor ports to avoid cross-threading. Once hand-tight, use line wrenches to torque fittings to specification.
   ⚠Do not overtighten AC fittings as aluminum threads can strip easily. Use torque wrench for proper specification.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Reconnect electrical connector
    Reconnect the AC compressor clutch electrical connector. Ensure it clicks firmly into place and the locking tab is fully engaged.
11. 11

    Install serpentine belt
    Route new or existing serpentine belt around all pulleys following the belt routing diagram on the radiator support. Rotate tensioner clockwise and slip belt onto the last pulley. Release tensioner slowly to apply proper belt tension. Verify belt is properly seated in all pulley grooves.
12. 12

    Vacuum and recharge system
    Connect vacuum pump to AC service ports. Pull vacuum on system for minimum 45 minutes to remove all moisture and air. System should hold vacuum for 10 minutes without loss. If vacuum holds, recharge system with R-134a refrigerant to factory specification (approximately 17-19 oz total, verify on underhood label). Add refrigerant through low-side port only with engine running and AC on MAX.

Reassembly

1. Reinstall lower engine splash shield
2. Reinstall passenger side front wheel and torque lug nuts to specification
3. Lower vehicle from jack stands
4. Reconnect negative battery cable

Verification

• Start engine and turn AC system to MAX cool with fan on high
• Verify AC compressor clutch engages and pulley rotates smoothly without noise
• Check system pressures with manifold gauges: low side should be 25-35 PSI, high side 200-250 PSI at idle with ambient temperature around 75-85°F
• Verify cold air output from dashboard vents (typically 40-50°F colder than ambient)
• Inspect all AC line connections for signs of refrigerant oil leakage
• Use electronic leak detector or soap solution to check all fittings for leaks
• Verify no unusual noises from compressor during operation
• Test AC operation through multiple on/off cycles to confirm clutch engagement

More procedures for this vehicle