This procedure covers the removal and replacement of the AC hose assembly on a 2015 Kia Forte 1.8L, including refrigerant recovery, hose replacement, and system recharge.

Warnings

Tools required

Parts

• AC hose assembly × 1 — Use OEM specification for specific hose being replaced
• AC O-rings × 1 — Use OEM O-ring kit
• R-134a refrigerant × 1 — Approximately 1.3 lbs capacity
• PAG oil for AC system × 1 — ND-OIL 8 or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Raise and secure vehicle on lift or jack stands if accessing underside hoses
4. Verify which AC hose assembly requires replacement (suction, discharge, or liquid line)
5. Gather EPA-certified recovery equipment and verify proper operation

Procedure

1. 1

   Recover refrigerant from AC system
   Connect AC recovery machine to service ports on low and high pressure sides. Follow recovery machine instructions to completely evacuate all R-134a refrigerant from the system. Record amount of refrigerant and oil recovered for recharge reference. Verify system pressure reaches 0 psi before proceeding.
2. 2

   Access AC hose assembly
   For discharge/liquid lines: Open hood and locate hose connections near firewall and compressor. For suction line: May require accessing from underneath vehicle. Remove any plastic covers or heat shields blocking access to hose fittings using appropriate fastener tools.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)
3. 3

   Disconnect hose fittings at compressor
   Using appropriate wrench, loosen and disconnect AC line fittings at compressor. Support hose assembly to prevent stress on connections. Immediately cap open fittings to prevent moisture and debris entry. Remove and discard old O-rings from fittings.
4. 4

   Disconnect hose fittings at condenser or evaporator
   Locate opposite end of hose assembly at condenser (front of vehicle) or evaporator (firewall). Loosen and disconnect AC line fittings using appropriate wrench. Cap all open ports immediately. Note routing of hose assembly and any mounting brackets for reinstallation.
5. 5

   Remove hose mounting brackets
   Identify all mounting brackets securing the AC hose assembly to body or engine components. Remove bolts securing mounting brackets using appropriate socket. Keep hardware organized for reinstallation. Carefully remove old hose assembly from vehicle.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
6. 6

   Prepare new hose assembly
   Unpack new AC hose assembly and verify correct application. Install new O-rings on all fittings (both ends of hose). Lightly coat new O-rings with fresh PAG oil (ND-OIL 8 or equivalent) to ensure proper seal and prevent damage during installation. Do not over-lubricate.
7. 7

   Install new hose assembly
   Route new hose assembly following exact path of original hose. Ensure hose does not contact exhaust components, sharp edges, or moving parts. Verify proper clearance throughout routing path. Loosely install mounting brackets to hold hose in position but do not fully tighten yet.
8. 8

   Connect and torque fittings
   Hand-thread AC line fittings at both compressor and condenser/evaporator connections. Verify fittings thread smoothly without cross-threading. Using torque wrench, tighten AC line fittings to specification. Ensure fittings are fully seated before final torquing.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
9. 9

   Secure mounting brackets
   With hose assembly properly positioned and all fittings connected, torque all mounting bracket bolts to specification. Verify hose has no tension or stress at connection points and maintains proper clearance throughout its routing.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
10. 10

    Evacuate AC system
    Connect vacuum pump to AC service ports. Evacuate system to deep vacuum (minimum 29 inches Hg) and hold for at least 30 minutes. Monitor vacuum gauge to verify system holds vacuum without decay, indicating no leaks. If vacuum decays, locate and repair leak before proceeding.
11. 11

    Recharge AC system
    Using AC service machine, charge system with correct amount of R-134a refrigerant (approximately 1.3 lbs total system capacity, minus amount remaining if partial recharge). Add appropriate amount of PAG oil to replace oil lost with hose assembly (typically 1-2 oz). Follow machine instructions for proper charging procedure.
12. 12

    Reinstall covers and shields
    Reinstall any heat shields, plastic covers, or protective components removed during disassembly. Torque cover screws to specification. Ensure all components are properly secured and no tools or hardware remain in engine bay.
    Torque spec

    Cover Screws10 Nm (8 lb-ft)

Reassembly

1. Verify all AC line fittings are torqued to specification with new O-rings installed
2. Confirm hose assembly has proper clearance from exhaust and moving components
3. Ensure system was properly evacuated before recharging to remove moisture
4. Add UV dye to system if desired for future leak detection capability

Verification

• Start engine and turn AC to maximum cool with blower on high
• Verify compressor engages and system pressures are within normal range (Low: 25-35 psi, High: 200-250 psi at idle, ambient 80°F)
• Check all new connections for refrigerant leaks using electronic leak detector or soap solution
• Verify cold air output from vents reaches appropriate temperature (typically 40-50°F at vent)
• Inspect hose assembly for any signs of vibration, contact, or stress while engine is running
• Allow system to operate for 10 minutes and recheck for leaks and proper operation

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