Introduction
The 2003 Kia Sedona came with two engines: the 3.5-liter and the 3.8-liter engine. The process on how to change out a Kia Sedona air compressor is a bit different for each engine, so make sure you check which engine you have before you read the following DIY repair tips. You can find the engine size on the sticker on the underside of the hood. Order all parts before you start. You must replace the receiver/drier and the expansion valve when changing the compressor. If you do not change at least the receiver/drier, you void the warranty on the compressor.
Tools Needed
Set of sockets
Set of line wrenches
Shop rags
Torque wrench
3.5-Liter Engine
Drive the vehicle to a shop certified for air conditioning repairs. Ask the shop to evacuate the Freon for you. Loosen the tensioner pulley, using the appropriate socket, to loosen tension on the belt. Lift the belt off the air compressor pulley.
Depending on the type of compressor you have, the high and low-pressure lines may be fitted onto the back of the compressor via a manifold, or they may go directly into the back of the compressor. If there is a manifold, remove the bolt holding the manifold onto the compressor and set the lines and manifold aside. If the lines go directly into the compressor, remove them with the appropriate line wrench.
Stuff a shop rag in the ends of the lines to keep them from getting contaminated. Unplug the wiring harness connector on the compressor. Remove the compressor retaining bolts, then lift the compressor out of the vehicle.
Pour the recommended amount of oil into the new compressor, if it did not come with oil in it. The instructions for your brand of compressor should be in the box with the compressor. Cap the oil plug, then set the compressor on its clutch and let it sit for 20 minutes. This ensures that the oil penetrates the clutch seal – if it doesn’t, the Freon could leak.
Install the new compressor and tighten the bolts to 17 foot-pounds of torque. Reinstall the lines. Plug in the wiring harness on the compressor. Reinstall the accessory drive belt. Drive the vehicle to a shop authorized to work on the air conditioning system. Have the shop charge the system with Freon.
3.8-Liter Engine
Make sure you have the 3.8-liter engine before you follow these instructions on how to change out a Kia Sedona air compressor. Drive the vehicle to a shop certified in working on vehicle air conditioning systems. Have the shop evacuate the system. Loosen the tensioner to loosen tension on the accessory drive belt. Lift the belt off the air compressor pulley.
Remove the suction line (the thicker line), then the discharge line from the compressor, using the appropriate line wrench. Plug the lines with shop rags to keep them from getting contaminated.
Unplug the wiring harness connector on the compressor. Remove the four mounting bolts holding the compressor on the block. Pay attention to the length of the bolts when you remove them. They must be put in the same place when you install the new compressor. Lift the compressor out of the engine compartment.
Follow the instructions for filling the compressor with oil – the instructions come with the brand compressor you purchased. Set the compressor up on its clutch for 20 minutes, to allow the oil to soak into the seals.
Install the compressor and tighten the bolts firmly. Plug in the wiring harness connector. Reinstall the accessory drive belt. Drive the vehicle to a certified shop and have them charge the system with Freon.
Receiver/Drier
Whenever you change the compressor, you must also change the receiver/drier or else you will void the warranty on the compressor. To change the receiver/drier, remove the lines at the receiver/drier, using the appropriate line wrench. Loosen the bolt on the bracket and lift the receiver/drier out of the bracket.
Insert the new receiver/drier into the bracket and tighten the bolt. Reinstall the lines.
Expansion Valve
The expansion valve should also be replaced, but it is not a warranty requirement for the compressor. The expansion valve is located near the firewall, just before the evaporator. It has special screws and many small gaskets – plastic and rubber – to keep it from leaking and to attach it to the air conditioning system. If you must replace the expansion valve, it is recommended that you have an experienced technician replace it.
Tips
Part of knowing how to change the air compressor on a Kia Sedona is knowing that the O-ring must always be replaced. When installing new O-rings, coat them with refrigerant oil . Most compressors come with the oil in a small bottle, and there is usually enough to fill the compressor and coat the O-rings. If you do have to buy extra oil, be sure you get the same brand and type that comes with your compressor.