Download 02-03 Honda Civic Si Service Manual
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HVAC(Heating, Ventilation, andAir Gonditioningl HeatingandAir Conditioning 21-2 SpecialTools Comoonent Location lndex ........z t-'5 A/CService Tiosand Precautions z t-o A,/CRefrigerant Oil ReDlacement z t-o Troubleshooting General lnformation 21-8 Index .......21-9 DTCTroubleshooting SymptomTroubleshooting 1ndex.............. 21-10 21-11 SystemDescription..................... CircuitDiagram 21-14 D T CT r o u b l e s h o o t i n. .g. . . . . . . . . . .z. .t .- .t .o Recirculation ControlMotor .......... CircuitTroubleshooting 21-25 HeaterControlPowerandGround Troubleshooting ........21-27 Circuits Condenser FanCircuit Troubleshooting ...................... 21-28 Fans Radiator andCondenser CommonCircuit ...................... 21-29 Troubfeshooting Compressor ClutchCircuit T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . 2 . .1. .-.3. .0 A,/CPressureSwitchCircuit ...................... 21-32 Troubleshooting Air Mix ControlMotor ............. 21-34 TestandReolacement ModeControlMotor ............. 21-35 TestandReplacement Recirculation ControlMotor ............. 21-36 TestandReolacement Evaporator Temperature Sensor andTest ............. 21-31 Reolacement Test ................. 21-38 PowerTransistor HeaterControlPaneland PushSwitchAssemblv RemovalandInstallation........21-38 DustandPollenFilter Reolacement ..21-39 BlowerUnitRemovaland ......21-39 lnstallation BlowerUnitComoonents R e D l a c e m e .n. t. . . . . . . . . . . . . . . . .2. .1. .- .4. 1. . . Evaporator Core ..21-42 Reolacement *HeaterUnit/Core ..21-43 ReDlacement HeaterValveCable .....21-46 Adjustment .......... 21-47 CompressorReplacement 21-48 Comoressor ClutchCheck .......... Comoressor ClutchOverhaul.....21-49 ThermalProtector Compressor R e o 1 a c e m e.n. .t . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . . ReliefValve Comoressor R e o l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . . 21-52 Reolacement............ Condenser Recovery .................. 21-53 Refrigerant ...................... 21-54 SystemEvacuation 21-55 SystemCharginS......................... 21-56 LeakTest.................. Refrigerant 21-57 A,/CSvstemTests ........................ HVAC{Heating,Ventilation,and Air Conditioning) SpecialTools Ret.No. o Tool Number DescriDtion 07sAz-001000A BackprobeSet ---2 att-,,/'Tt e^t"' T 21-2 KCe "-t--' Otv 2 Heatingand Air Gonditioning ComponentLocationIndex VALVE SERVICE {LOW.PRESSUBE SIDEI EVAPORATOR CORE (Built-in theheaterunit) B e p l a c e m epnat ,g e2 1 4 2 SERVICE VALVE {HIGH-PRESSURE SIDEI RECEIVER/DRYER COMPRESSOR Beplacement,page21 47 CONOENSEB ClutchCheck,page21-48 page 21-52 Replacement, C l u t c hO v e r h a u lp, a g e2 1 - 4 9 ThermalProtectorCheck,page21-48 page21 51 ThermalProtectorReplacement, R e l i eV f a l v eR e p l a c e m e npta, g e2 1 5 1 Heatingand Air Conditioning ComponentLocationIndex(cont'dl RADIATORFAN RELAY Test,page22-51 CLUTCHRELAY Tesl, page 22-51 MOTORRELAY Test, page 22-5I '-t /l l- I T I -::-- t_]]l BOX UNDER.HOOD FUSE/RELAY - -l - CONDENSERFAN Test, page 22-51 \ .\\ ... A/C PRESSURE SWITCH - RADIATORFAN CONOENSERFAN 21-4 HEATER UNIT/CORE page21-43 Beplacement, BLOWEN UNIT page21-39 Removal andInstallation, BLOWERUNITCOMPONENTS page21-41 Replacement, HEATERVALVECABLE page21-46 Adjustment, DUSTAND POLLEN FILTER page21'39 Replacement, RECIRCULATION CONTROLMOTOR Test,page21-36 page21-36 Replacement, MODE CONTROLMOTOR Test,page21-35 page21-35 Replacement, POWERTRANSISTOR Test,page 21-38 AIR MIX CONTROLMOTOR Test,page21'34 page21'34 Replacement, EVAPORATORTEMPERATURE SENSOR page 21-37 Replacement, Test,page21-37 PUSH SWITCHASSEMBLY Removaland Installation,page21'38 HEATERCONTROLPANEL RemovalandInstallation,page21 38 21-5 HeatingandAir Conditioning A/C ServiceTips and Precautions A/C Refrigerant Oll Replacement R e c o m m e n d eP d A Go i l : K E I H I NS P 1 0 : Compressedair mixed with R-134aforms a combustible vapor. T h e v a p o rc a n b u r n o r e x p l o d ec a u s i n gs e r i o u s injury. Never use compressedair to pressuretest R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r c o n d i t i o n i n sg y s t e m s . A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor. T h e a i r c o n d i t i o n i n sg y s t e mu s e sH F C - 1 3 4(aR - 1 3 4 a ) r e fr i g e r a n at n d p o l y a l k y l e n e g l y c(oPl A G )r e fr i g e r a n ot i l , w i t h C F C ' 1 2( R - 1 2r)e f r i g e r a n t w h i c ha r e n o t c o m p a t i b l e r e f r i g e r a not r m i n e r a l l i l .D o n o t u s eR - ' 1 2 andminerao oil in this system,and do not aftemptto use R 12 s e r v i c i n ge q u i p m e n td; a m a g et o t h e a i r c o n d i t i o n i n g t ill result. s y s t e mo r y o u r s e r v i c i n ge q u i p m e nw U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . - l i s t eadn d i s certifiedto meet the requirementsof SAE J2210to r e m o v eR - 1 3 4 af r o m t h e a i r c o n d i t i o n i n sg y s t e m . lf accidentalsystem dischargeoccurs,ventilatethe w o r k a r e ab e f o r er e s u m i n gs e r v i c e . . P/N38897-Pl3-A01AH:'120m0 i4 fl oz) . P/N38899-P13'A01: 40 m0 i1 1/3fl oz) Add the recommendedrefrigerantoil in the amount listedif you replaceany of the following parts. . T o a v o i dc o n t a m i n a t i o nd.o n o t r e t u r nt h e o i l t o t h e c o n t a i n eor n c ed i s p e n s e da, n d n e v e rm i x i t w i t h o t h e r refrigerantoils. . l m m e d i a t e la y f'teu r s i n gt h e o i l , r e i n s t a l l t h e c a po n the container,and seal it to avoid moisture aosorpron. . D o n o t s p i l lt h e r e f r i g e r a not i l o n t h e v e h i c l e i;t m a y damagethe paint. lf it gets on the paint,wash it off immediately. , . 9l m p . o z ) C o n d e n s e r. . . . . . . . . . . 2m5A\ 5 1 6t l . o z 0 '1.4 E v a p o r a t o r. . . . . . . . .4. 5 . m0 (1113Il.oz, lmp.oz) '10 L i n eo r h o s e . . . . . . . . . m 0 { 1 / 3f l . o z , 0 . 4l m p . o z ) '10 R e c e i v e r / D r y e.r. . . m 0 ( ' 1 1f3l . o z , 0 . 4l m p . o z ) Leakagerepair ....25 m0,1516 Il oz,0.9 lmp.oz) . .o rc o m p r e s s orre p l a c e m e n l , C o m p r e s s o r. . . . . . . F s u b t r a ctth e v o l u m eo f o i l d r a i n e d from the removedcompressorfrom 1 3 0m 0 ( 4 1 / 3 f l . o z4, . 6 l m p . o z )a, n d d r a i nt h e c a l c u l a t e vdo l u m eo f o i l '130 f rom the new compressor: m0 i . 4 1 1 f3l . o z , 4 . 6l m p . o z ) V o l u m eo f removedcompressor= Volume to d r a i nf r o m n e w c o m p r e s s o r . R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r c o n d i t i o n i n g systemsshould not be pressuretested or leaktested withcompressed air. NOTE:Evenif no oil is drainedfrom the removedcompressor,don't d rain more than 50 m0 \1 2/3 fl.oz, ' 1 . 8l m p o z ) f r o mt h e n e w compressor. A d d i t i o n ahl e a l t ha n d s a f e t yi n f o r m a t i o nm a y b e obtainedfrom the refrigerantand lubricant manufacturers. . Always disconnectthe negativecablefrom the parts. b a t t e r yw h e n e v e r e p l a c i n ga i r c o n d i t i o n i n g . Keepmoistureand dirt out of the system.When d i s c o n n e c t i nagn y l i n e s ,p l u go r c a pt h e f i t t i n g s immediately;don't removethe caps or plugs until iust be{oreyou reconnecteach line. ' B e f o r ec o n n e c t i n g a n y h o s eo r l i n e ,a p p l ya f e w d r o p s of relrigerantoil to the O-ring. . W h e nt i g h t e n i n go r l o o s e n i n ga f i t t i n g ,u s ea s e c o n d wrench to supportthe matchingfitting. . W h e n d i s c h a r g i ntgh e s y s t e m u , s ea R - ' 1 3 4 a station;don't refrigerantrecovery/recycling/charging releaserefrigerantinto the atmosphere. 21-6 r\ REMOVED COMPBESSOR A l i \.. rJ \tb NEW COMPRESSOR /- a\ i \ t l r / \:)-) -/ 'r:l_ _ 0L I "o*tttu" _*lH ,lEL.- I I I DRAINING A: 130 m0 {4 l/3 tl.oz,4.6lmp.oz) I voLUME ],^ \ RECEIVER LINEA RECEIVER/DRYER CONDENSER LINE Dischargehoseto the compressor{6 x 1.0 mm) : 9.8 N.m {1.0kgf.m,7.2 lbl.ft} Dischargehoseto the condenser(5 x 1.0mml : 9.8 N.m {1.0kgt.m,7.2 lbf ft) Condenserline to the condenser(6 x 1.0mm) : 9.8 N.m {1.0kgf,m,7.2 lbt.ft} Condenserfine to the receiver/dryer{6 x 1.0mm} : 9.8 N.m (1.0kgt.fi,7.2lbt.ltl ReceiverlineAtothe receiver/dryer{6 x 1.0mm} : 9.8 N.m {1.0kgf.m. 7.2 lbf.ft} Receiverline A to the receiveiline B : 13 N.m (1.3kgr.m,9.4 lbf.ft) Receiverline B and the suctionline to the evaporator(6 x 1.0mm) :9.8 N.m 11.0kgf.m,7,2 lbf.ft) Suction line to the suction hose : 3l N m {3.2 kgf.m, 23 lbf ftl Suctionhose1o the compressor(6 x 1.0mm) : 9.8 N.m 11.0kgf.m.?.2 lbf.lt) Compressorto the compressor b.acket {8 x 1.25 mm) : 22 N m {2.2 kgt.m, 16 lbf.ft) Compr€ssorbracketto the engineblock {10 x 1.25mm} : ,14N.m 14.5kgf.m,33 lbf.ft) 21-7 Heatingand Air Conditioning GeneralTroubleshootingInformation How to Retrievea DTC The heatercontrol panel has a self-diagnosisfunction.To run the self-diagnosisfunction,do the following: 1 . T u r nt h e f a n s w i t c hO F F . 2. Pressandholdthe recirculationcontrol switch andthe rearwindow defoooerswitch down. 3 . T u r nt h e i g n i t i o ns w i t c ho N { l l i . 4. Releaseboth switches.The recirculationindicatorand the rearwindow defoggerindicatorcome on. The recirculationindicatorgoes off 3 secondslater and the Ay'Cindicatorcomes on. then the self-diagnosiswill begin. About 10 secondslater,the self-diagnosiswill finish and the A,/Cindicatorgoes off. .lfanytroubleisfound.therecirculationindicatorblinksthediagnostictroublecode(DTC)toindicateafaulty circuil or comDonent. . lf the system is OK, the recirculationindicatorstaysoff. atc INOICATOR BECIRCULATION INDICATOB /A\ -:@ RECIRCULATION CONTROLSWITCH REARWINDOW INDICATOR OEFOGGER @r REARWINDOW DEFOGGER SWITCH Examole of DTC indication Pattern IDTC7) DTC 7 Recirculation + indicatot Recirculation+ indicalor go6s oft -----> Reseiting the Selt-diagnosis Function Turn the ignition switch OFFto cancelthe self-diagnosisfunction.After completingrepairwork, run the self-diagnosis f u n c t i o na o a i nt o m a k es u r et h a t t h e r ea r e n o o t h e rm a l f u n c t i o n s . 21-8 DTCTroubleshootingIndex DTC{Recirculation IndicationBlinks) 7 8 9 10 11 12 13 14 Detection ltem A n o p e n i n t h e a i r m i x c o n t r o lm o t o rc i r c u i t A short ln the air mix control motor circuit A p r o b l e mi n t h e a i r m i x c o n t r o l i n k a q ed, o o r ,o r m o t o r An open or shon in the mode control motor circuit A p r o b l e mi n t h e m o d ec o n t r o l i n k a g ed, o o r s ,o r m o t o r A p r o b l e mi n t h e b l o w e rm o t o rc i r c u i t A problem in the EEPROMin the heatercontrol panel; the control oanel must be reolaced An ooen in the evaDoratortemDeraturesensorcircuit A short in the evaDoralortemoeraturesensorcircuit Page ( s e ep a q e2 1 - 1 6 ) ( s e eD a o e2 1 - ' 1 6 ) ( s e ep a q e2 1 -1 7 ) ( s e eo a q e2 1 - 1 8 ) ( s e ep a q e2 1 1 9 1 ( s e ep a q e2 1 - 2 0 ) ( s e ep a g e2 1 - 3 8 ) (seepaqe 21-23) ( s e eo a q e2 1 - 2 4 1 In case of multiple problems,the recirculationindicatorwill indicateonly the DTCwith the least number of blinks. ln caseof an intermittentfailure,the heatercontrol panelwill storethe DTCuntil the ignition is turned off. 21-9 Heatingand Air Conditioning \ Index SymptomTroubleshooting { Also check for Svmptom Diagnosticprocedure RecirculationControl Motor Recirculationcontrol doors do not C l e a n l i n e sasn d t i g h t n e s so f a l l changebetweenFreshand Recirculate CircuitTroubleshooting(seepage connectors 21 251 HeaterControlPowerandGround B l o w nf u s eN o .' 1 4( 1 0 Ai)n t h e Both heaterand Ay'Cdo not work (see CircuitsTroubleshooting page21-27) Condenserfan does not run at all (but radiatorfan runs with the Ay'Con) Both fans do not run with the A,/Con Compressorclutchdoes not engage (both fans run with A,/Con) A/C system does not come on (both fans and compressor) fuse/relay box under-dash Poorgroundat G501 C l e a n l i n easns dt i g h t n e sosf a l l conneclors . P o o rg r o u n da t G 3 0 1 . C l e a n l i n e sasn d t i g h t n e s so f a l l connectors R a d i a t oarn dC o n d e n s e Fra n s B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4 CommonCircuitTroubleshooting (20A)in the under-hoodfuse/relay ( s e ep a g e2 1 - 2 9 ) box P o o rg r o u n da t G 3 0 l C l e a n l i n e sasn dt i g h t n e s so f a l l connectors CompressorClutchCircuit C l e a n l i n e sasn dt i g h t n e s so f a l l T r o u b l e s h o o t i n(qs e eD a q e2 1 - 3 0 ) connectors Ay'CPressureSwitch Circuit B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4 (20A)in the under-hoodfuse/relay T r o u b l e s h o o t i n(gs e ep a g e2 1 - 3 2 ) box Poor ground at G301 C l e a n l i n e sasn dt i g h t n e s so f a l l connectors C o n d e n s eFr a nC i r c u i t Troubleshooting{seepage 21-28) a \ ! 21-10 a SystemDescription HeaterControlPanelInputsandOutputs HEATERCONTFOLPANELCONNECIORS CONNECTOR A {r/rP) CONNECTORB (22P) W res deoitema eterm nals CONNECTOR Cavity _| Wire color \ln Y 2 3 LT GRN PNK/BLU BLU GRNA/EL GRNA/VHT BLUI/EL BLU/RED 5 6 7 8 I GRN 10 11 YEL/RED YEVBTU YEL/BLK BLK BLK/YEL . 14 CONNECTOR B Cavity Sional AIRMIXPOTENTIAL +5V S E N S OC RO M M O N GROUND OUTPUT AIR MIX HOT OUTPUT INPUT INPUT INPUT OUTPUT INPUT OUTPUT OUTPUT OUTPUT INPUT OUTPUT INPUT INPUT A,/CPRESSURE SWITCH RECIRCULATE FRESH POWER TRANSISTOR BLOWERFEEDBACK AIR MIX COOL MODEDEF MODEVENT REARWINDOWDEFOGGER RELAY GROUND l G 2( P o w e r ) on Wire color Siqnal 1 2 3 4 5 6 7 8 9 BLIVRED --T PNVBLK R E A RW I N D O WD E F O G G ES RW I T C HL E D A./CSWITCHLED RECIRCULATIO CN ONTROL S W I T C HL E D AIR MIX POTENTIAL BRN EVAPORATOR TEIMPERATURE SENSOR INPUT INPUT INPUT OUTPUT OUTPUT GAUGE ASSEMBLY al' 'TDr ri LT GRN L TG R N / B L K 10 11 14 ic 16 17 18 19 20 RED RED/BLK BLU LT GRN/RED YEVRED YEUGRN WHT/BLU RED/BLU RED/YEL BRN^,^/HT 22 REDA/r'HT TAILLIGHTSRELAY INPUT REARWINDOWDEFOGGER SWITCH INPUT A/C SWITCH RECIRCULATIO CN ONTROL SWITCH INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT MODE4 MODE3 M O D E2 M O D E1 I G N( P o w e d (Not used) (cont'd) 21-11 Heatingand Air Gonditioning SystemDescription(cont'dl The air conditioningsystem removesheatfrom the passengercompartmentby circulatingrefrigerantthrough the system as shown below. BLOWER FAN \ \ \ r\,u / EXPANSIONVALVE (Metersthe required amount of refrigerant into the evaporator) APOBATORTEMPERATURE SENSOR THERMALPROTECTOR (Opensthe compressorclutchcircuit when the compressottemperature becomestoo high) A/C PRESSURESWITCH When the refriqerantis below 196kPa(2.0kgi/cm',28psi) or above3,140kPa(32 kgf/cm' 455 psi),the Py'cpressure switchopensthe circuitto the Py'Cswitch and stopsthe air conditioningto protectthe compressor- RELIEF VALVE (Relieves pressure at thecompressor w h e nt h ep r e s s u ri e st o oh i g h ) A/C COMPRESSOR (Suctionand comoression) RECEIVER/DRYER (Trapsdebris,and \-^ removesmorsturel /CONDENSER (Radiationof heat) I vAPoR HrcHPRESSURE -:--l [ '.... Low PREsSUBE LrourD tffi Low PREssURE vAPoR refrigerantwhich does not containchlorofluorocarbons.Pay attentionto the This vehicleuses HFC-134a(R-'134a) following serviceitems: . D o n o t m i x r e f r i g e r a n tCs F C - 1 2 ( R - 1 2a) n d H F C - 1 3 4(aR - 1 3 4 aT) .h e ya r e n o t c o m p a t i b l e . '!0) . U s eo n l y t h e r e c o m m e n d e p d o l y a l k y l e n e g l y c(oPl A G) r e f r i g e r na t o i l ( K E l H l NS P designedfortheR-134a (PAG) recommended refrigerant with retrigerant oil will resultin compressor.Intermixingthe oil any other compressorfailure. . AllAy'Csystem parts (compressor,dischargeline, suction line,evaporator,condenser,receiver/dryer. expansion valve,O-ringsfor joints) have to be designedfor refrigerantR 134a.Do not exchangewith R-'12parts. . Use a halogengas leakdetectordesignedfor refrigerantR-134a. . R-12and R-134arefrigerantservicingequipmentare not interchangeable. Use only a recovery/recycling/charging s t a t i o nt h a t i s U . L . - l i s t eadn d i s c e r t i f i e dt o m e e tt h e r e q u i r e m e n tosf S A EJ 2 2 1 0t o s e r v i c eR - 1 3 4 a i r c o n d i t i o n i n g system. . Always recoverthe refrigerantR-134awith an approvedrecovery/recycling/charging stationbeforedisconnecting any Ay'Cfifting. 21-12 HeatingandAir Conditioning GircuitDiagram UNDEN rcODFUSVRELIYSOX UNOER DASN fUSE/8EIlYBOX |GNUION SWTCfi lG2HoI ii 0l\lllll +. \ C}F rG2/ BLK/RED l ; .I / Y I \ IHEFMAI PBorEcro8 I I *n*,*, lTl | <l I CLUTCH tf _l . G301 MUITIPLD( CONTFOI UNITI -!10. T RADIATOS\ NADIATOS ) tAl'/ / swtlcll oT0n I B LX I G301 21-14 j 19S"F 193"C) l I I n A/CPnESSUEt swTOt irgF 8Ll T t...iCF BLU CONDEN$N MOTOB I I 8u( I ilnthoundor dasiluse/lelay box - BU/YEL -8lU/wH'I EVAPORATOB TEMPERATUNESENSOR sn 4-Lrenil m ::-:::: ., . a/c YEUBLU YEL/NED M DEF MODEl BED/YEI Mq)EI RED/8LU M00€2 M00t3 WHT/8LU MOOE3 YEL/GRN MOOEI M00l co TnoL MOTOS s LTGRI'l ffftH,, F*u,* GNNMHT 8U I GRN/YEL 8LK--..-...-l ( f coNNEcroFrir.Pt mxr{EcroB ! {2P) G5'1 G602 21-15 Heatingand Air Conditioning DTCTroubleshooting DTC7:An Openin theAir Mix ControlMotor Circuit DTC8:A Shortin theAir Mix ControlMotor Circuit 1. Test the air mix control motor {seepage 2'l-341. 1. Testthe air mix control motor(see page 21-341. ls the air mix control motor OK? YES-Go to step 2. N O - R e p l a c et h e a i r m i x c o n t r o lm o t o r . l 2. Disconnectthe air mix control motor 5P connector. 3. Disconnectheatercontrol panel connectorsA {14P) a n dB ( 2 2 P ) . 4. Checkfor continuitybetweenthe following terminalsof heatercontrol panel connectorsA (14P)and B (22P)and the air mix control motor 5P connector, 14P: 5P: No.5 N o .1 No.4 No.2 No.2 No.3 N o .1 No.9 ls the ait mix control motor OK? YES-Go to step 2. NO-Replace the air mix contorol motor.I 2. Disconnectthe air mix control motor 5P connector. 3. Disconnectheatercontrol panelconnectorsA (14P) andB (22P). 4. Checkfor continuitybetweenbody ground and heatercontrol panelconnectorA (14P)terminals No. 1, 2, 3, and 9 individually,and betweenbody ground and heatercontrol panelconnectorB (22P) t e r m i n a lN o . 6 . A {I4PI HEATERCONTROL PANELCONNECTOR 22P: No.6 5P: No.3 W i r e s i d eo f f e m a l et e r m i n a l s HEATERCONTFOL PANELCONNECTORB I22P1 Wire side ol lem.letehi.6ls ls there continuity? YES-Check for loosewires or poor connectionsat heatercontrol oanel connectorsA (14P)and B (22P) and at the air mix control motor 5P connector.lf the connectionsare good. substitutea known-goodair mix control motor, and recheck,lf the symptom/ indicationgoes away, replacethe originalair mix control motor. lf the symptom/indicationcontinues, substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l N O R e p a i ra n y o p e n i n t h e w i r e ( s )k e t w e e n t h e heatercontrol panel and the air mix control motor.l 21-16 W i r e s i d eo i l e m a e l e r m i n a l s ls therc continuity? Y E S - R e p a i ra n y s h o r t t o b o d y g r o u n dl n t h e wire(s)betweenthe heatercontrol panel and the air mix control motor.l N O - G o t o s t e p5 . 5. Turn the ignition switch ON (ll),and checkthe same terminalsfor voltage. HEATERCONTROLPANELCONNECTOR A {14PI DTC9: A Problemin the Air Mix Control Linkage, Door,or Motor 1, Test the air mix control motor (seepage 21-34). ls the air mix control motor OK? YES-Substitute a known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l NO-Replace the air mix control motor, or repair t h e l i n k a g ea n d d o o r . l Wire side of femaleterminals HEATERCONTROLPANELCONNECTOR B I22PI Wiresideof femaleterminals ls there any voltage? YES-Repair any short to power in the wire(s) betweenthe heatercontrol panel and the air mix control motor. This short may also damagethe heatercontrol panel.Repairthe short to power before replacingthe heatercontrol panel.l NO Substitutea known-goodair mix control motor, and recheck.lf the symptom/indicationgoes away, replacethe originalair mix control motor. lf the symptom/indicationcontinues,substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe originah l e a t e rc o n t r o lp a n e l . I 21-17 Heatingand Air Conditioning DTCTroubleshooting.(cont'd) DTC10:An Openor Shortin the Mode ControlMotorCircuit 1. Test the mode control motor (seepage 21-35). 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h e s a m e t e r m i n a l sf o r v o l t a g e . HEATEB CONTROL PANEL CONNECTOR A {14P) ls the mode cottol motor OK? YES Go to step 2. NO Replacethe mode control motor.I 2. Disconnectthe mode control motor 10Pconnector. s (14P) 3 . D i s c o n n e cht e a t e rc o n t r o lp a n e lc o n n e c t o r A and B \22P1. Checkfor continuitybetweenbody ground and h e a t e rc o n t r o lp a n e lc o n n e c t oA r ( 1 4 P t)e r m i n a l s N o . 2 , 1 0 ,a n d 1 1 i n d i v i d u a l l ya,n d b e t w e e nb o d y g r o u n da n d h e a t e rc o n t r o lp a n e lc o n n e c t o B r (22P) '17, 1 8 ,1 9 ,a n d 2 0 i n d i v i d u a l l y . t e r m i n a l sN o . HEATER CONTROL PANEL CONNECTOR A {14PI Wire side of femaleterminal HEATERCONTROLPANELCONNECTOR B {22PI 3 tl 12 5 X 15 T6 6 1 1 1 8 t 9 2A 21 22 RED/YEL WHT Wiresideof femaleterminals Wire side ol lemale terminals HEATERCONTROLPANELCONNECTOR B {22P) ls there any voltage? YES-. Repairany short to power in the wire(s) betweenthe heatercontrol panel and the mode control motor. This short may also damagethe heatercontrol panel.Repairthe short to power before replacingthe heatercontrol panel.l NO- Go to step 6. W i r e s i d e o f f e m a L el e r m i n a l s ls there continuity? Y E S R e p a i ra n y s h o r t t o b o d y g r o u n di n t h e wire(s)betweenthe heatercontrol panel and the mode control motor.l NO 21-18 Go to step 5. Turn the ignition switch OFF,and checkfor continuitybetweenthe following terminalsof heatercontrol panel connectorsA (14P)and B (22P) and the mode control motor 10Pconnector. 14P: 10P: '10 N o .2 No. No.10 No,1 N o .1 1 No.2 22P: N o .1 7 N o .1 8 No.19 N o .2 0 10P: No.8 No.6,9 No.5 N o .4 , 7 DTC11:A Problemin the ModeControl Linkage, Doors,or Motor 1. Testthe mode control motor (seepage 21-35). ls the mode control motor OK? YES Substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l NO Replacethe mode control motor, or repairthe l i n k a g ea n d d o o r s . l HEATER PANELCONNECTOR A (14PI CONTROL Wiresideof lemaleterminals MODECONTROLMOTORlOPCONNECTOR Wiresideof femaleterminals HEATERCONTROLPANELCONNECTORB {22PI Wire side of femaleterminals ls there continuity? YES-Check for loosewires or poor connectionsat heatercontrol panelconnectorsA (14P)and B (22P), and at the mode control motor 10Pconnector.lf the connectionsare good, substitutea known-good mode control motor, and recheck.lf the symptom/ indicationgoes away. replacethe original mode control motor.lfthe symptom/indicationcontinues, substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe originalheatercontrol panel.l NO Repairany open in the wire(s)betweenthe heatercontrol Daneland the mode control motor.l 21-19 HeatingandAir Gonditioning DTCTroubleshooting{cont'd) DTC12:A Problemin the BlowerMotor Circuit '1. C h e c kt h e N o . 1 2 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d fuse/relaybox, and the No. 14 (10A)fuse in the under-dashf use/relaybox. 7. Checkfor continuitybetweenthe No. 3 terminal of the power transistor4P connectorand body ground. POWERTRANSISTOR4P CONNECTOR 2 Are the tuses OK? 3 o NO Replacethe fuse(s),and recheck.l 2. Connectthe No. 2 terminal of the blower motor 2P connectorto body ground with a jumper wire. BLOWERMOTOB2PCONNECTOR 4 BLK YES-Go to step 2. Wire side ol temaleterminals ls there continuity? YES-Go to step 8. JUMPER] BLU/BLK NO-Check for an open in the wire betweenthe power transistorand body ground. lf the wire is OK, checkfor poor ground at G502.I 8 . Connectthe No. 1 and No. 3 terminalsof the power transistor4P connectorwith a jumper wire. Wiresideol femaleterminals TRANSISTOR 4PCONNECTOR POWER 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . Does the blowet motor run? YES Go to step 4, NO Go to step 17. 4. Turn the ignition switch OFF. Wiresideof femaleterminals 5. Disconnectthe jumper wire. 6. Disconnectthe power transistor4P connector. 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . Does the blower motor tun at high speed? Y E S - G o t o s t e p1 0 . NO-Repair open in the wire betweenthe power transistorand the blower motor.l 1 0 . Turn the ignition switch OFF. 1 1 . Disconnectlhe jumper wire. 21-20 1a Disconnectheatercontrol panelconnectorA (14P). 1 3 .Checkfor continuitybetweenthe No. 7 and No. 8 terminalsof heatercontrol panel connectorA (14P) a n d b o d y g r o u n di n d i v i d u a l l y . HEATER CONTNOL PANEL CONNECTOR A {14PI 1 5 . Reconnectheatercontrol panel connectorA (14P). lo. Test the power transistor(seepage 21-38). ls the power transistorOK? YES Checkfor loosewires or poor connectionsat heatercontrol panel connectorA (14P)and at the power transistor4P connector.lf the connections are good, substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l NO Replacethe power transistor.I 1 7 . Disconnectthe jumper wire. 1 8 . Disconnectthe blower motor 2P connector. 1 9 . Measurethe voltagebetweenthe No, 1 terminal of the blower motor 2P connectorand body ground. ls there continuity? YES Repairany shortto body ground in the wire(s)betweenthe heatercontrol panel and the power transistor.I BLOWERMOTOR2PCONNECTOR BLU/WHT NO Go to step 14, 1 4 . Checkfor continuitybetweenthe following terminalsof heatercontrol panelconnectorA ( 14P) and power transistor4P connector. 'l4Pt 4P: No.4 No.7 No.8 No.2 HEATER CONTROL PANEL CONNECTOR A (14P) Wiresideof femaleterminals Wire side ot femaleterminals z 3 I T 8 9 4 1 5 1 6 r ol x l I ls thete battery voltage? 1 2 l1 3l 1 4 BLU/YEL YES- Replacethe blower motor.l ) 8LU/RED NO Go to step 20. 20. Turn the ignitionswitch OFF. ILU/YEL 4PCONNECTOR POWER TRANSISTOR Wiresideof femaleterminals 2 1 .Removethe blower motor relayfrom the underhood fuse/relaybox, and test it (seepage 22-511. ls the relay OK? ls thete continuity? YES Go to step 22. YES Go to step 15. NO- Replacethe blower motor relay.l NO Repairany open in the wire(s)betweenthe heatercontrol paneland the power transistor.l (cont'd) 21-21 Heatingand Air Conditioning DTCTroubleshootinglcont'd) 22. Measurethe voltage betweenthe No. 3 terminal of the blower motor relay 4P socketand body ground. 25. Turn the ignition switch OFF, 26. Checkfor continuitybetweenthe No. 1 terminal of the blower motor relay 4P socketand body ground. BLOWERMOTORRELAY4PSOCKET 2 4 1 BLOWERMOTORRELAY4PSOCKET 3 ls there battety voltage? YES-Go to step 23. ls there continuity? NO Replacethe under-hoodfuse/relaybox.t YES-Repair open in the BLUIr'/HTwire between the blower motor relay and the blower motor.l 23. Turn the ignitionswitch ON {ll). Measurethe voltage betweenthe No. 2 terminal of the blower motor relay 4P socketand body ground, BLOWERMOTORRELAY4PSOCKET ls therebattery voltage? YES-Go to step25. NO Repairopenin thewire betweenthe No.14 fusein the under-dash fuse/relay boxandthe blowermotorrelay.I 21-22 NO Checkfor an open in the wire betweenthe blower motor relay and body ground. lf the wire is O K ,c h e c kf o r p o o r g r o u n da t G 3 0 1 . 1 \ DTC14:An Openin the Evaporator Temperature SensorCircuit 1. Removethe evaporatortemperaturesensor(see p a g e2 1 - 3 7 ) . 2. Measurethe resistancebetweenthe No. l and No. 2 terminalsof the evaporatortemperature sensor. x D i pt h e s e n s o ri n i c ew a t e r ,a n d m e a s u r e resistance.Then pour hot water on the sensor,and c h e c kf o r c h a n g ei n r e s i s t a n c e . 4. Checkfor continuitybetweenthe No. 7 terminal of heatercontrol panelconnectorB (22P)and the No. 1 terminal of the evaporalortemperature s e n s o r2 P c o n n e c t o r . B {22P) HEATERCONTROLPANELCONNECTOR Wiresideof femaleterminals EVAPORA TORTEMPERATURE SENSOR ll#l t-l SENSOR 2PCONNECTOR EVAPORATOR TEMPERATURE Wiresideof femaleterminals lI UT-TU l , l , l l ---r---T--I t ^ 11c))-l ls there continuity? \9/ T e r m i n asl i d eo f m a l et e r m i n a l s YES Go to step 5. NO Repairopen in the wire betweenthe heater control panel and the evaporatortemperature sensor.I 5. Disconnectheatercontrol panelconnectorA (14P). RESISTANCE k0 50 10 68 20 86'F 30'c TEMPERATURE ls the tesistancewithin the specificationsshown on the graph? Y E S - G o t o s t e p3 . NO Replacethe evaporatortemperature sensor.I 3. Disconnectheatercontrol panelconnectorB {22P). (cont'd) 21-23 Heatingand Air Gonditioning DTCTroubleshooting{cont'd) 6. Checkfor continuitybetweenthe No. 2 terminal of heatercontrol panel connectorA (14P)and the No, 2 terminal of the evaporalortemperature sensor2P connector. HEATER CONTROL PANELCONNECTOR A {14PI Wiresideof femaleterminals LT GRN DTC15:A Shortin the Evaporator Temperature SensorCircuit 1. Removethe evaporatortemperaturesensor(see p a g e2 1 - 3 7 ) . 2. Testthe evaporatortemperaturesensor(seepage 21-37J. ls the resistance within the specifications shown on the graph? YES Go to step 3. NO Replacethe evaporatortemperature sensor.! EVAFORATOR TEMPERATURE SENSOR 2PCONNECTOR Wiresideof femaleterminals Disconnectheatercontrol panel connectorB l22Pl. 4. Checkfor continuitybetweenthe No. 7 terminal of ls there continuity? YES-Check for loosewires or Doorconnectionsat heatercontrol panel connectorA ('l4P)and B l22Pl and at the evaporatortemperaturesensor2P connector.lf the connectionsare good, substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l heatercontrol panel connectorB {22P)and body ground. HEATER CONTROL PANELCONNECTOR B (22P) \ NO Reoairooen in the wire betweenthe heater control panel and the evaporatortemperature sensor.I Wire side of femaleterminals ls there continuity? YES Repairshort to body ground in the wire betvveenthe heatercontrol paneland the evaporatortemperaturesensor.I NO-Substitute a known-goodheatercontrol panel, and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.I 21-24 RecirculationControlMotor CircuitTroubleshooting 1 . C h e c kt h e N o . 1 4 ( ' 1 0 A ) f u sien t h e u n d e r - d a s h f u s e / relay box. 8. Checkfor continuitybetweenthe No. 5 and No. 6 terminalsof heatercontrol panelconnectorA (14P) and body ground individually. ls the f use OK? YES Go to step 2. A I14P) HEATER CONTROL PANELCONNECTOR NO- Replacethe fuse, and recheck.l 2. Disconnectthe recirculationcontrol motor 5P conneclor. 3 . Turn the ignitionswitch ON (ll). lvleasurethe voltage betweenthe No. 5 terminal of the recirculationcontrol motor 5P connectorand body ground. RECIRCULATIONCONTROLMOTOR 5P CONNECTOR Wire side of femaleterminals ls there continuity? YES Repairany shortto body ground in the wire(s)betweenthe heatercontrol panel and the recirculationcontrol motor.l NO-Go to step 9. 9. Turn the ignition switch ON (ll),and checkthe same wires for voltage. Wiresideof femaleterminals A Il4PI PANELCONNECTOR HEATER CONTROL ls there battery voltage? YES Go to step 5. NO- Repairopen in the wire betweenthe No. 14 fuse in the under-dashfuse/relaybox and the recirculationcontrol motor .l 5 . Turn the ignitionswitch OFF. 6 . Testthe recirculationcontrol motor {seepage 2136), ls the recirculationcontrol motor OK? YES Go to step 7. NO- Replacethe recirculationcontrol motor, or r e p a i rt h e l i n k a g ea n d d o o r s . I 7 . Disconnectheatercontrol panel connectorA (14P). Wiresideof lemaleterminals ls therc any voltage? Y E S R e p a i ra n y s h o n t o p o w e ri n t h e w i r e ( s ) betweenthe heatercontrol panel and the recirculationcontrol motor. This shon may also d a m a g et h e h e a t e rc o n t r o lp a n e l .R e p a i rt h e s h o n to power before replacingthe heatercontrol p an e l .I N O - G o t o s t e p1 0 . {cont d r 21-25 Heatingand Air Conditioning RecirculationControl Motor CircuitTroubleshooting(cont'd! 10. Turn the ignition swirchOFF. 11. Checkfor continuitybetweenthe following terminalsof heatercontrol panel connectorA ( 14P) and the recirculationcontrol motor 5P connector. 'l4Pt 5P: No.5 N o .1 No.6 No.2 HEATER CONTROL PANEL CONNECTOR A {14P} Wiresideol temaleterminats RECIRCULATION CONTROL MOTOR5PCONNECTOR Wiresideol lemaleterminals ls there continuity? YES Checkfor loosewires or poor connectionsat heatercontrol panel connectorA ( 14P)and at the recirculationcontrol motor 5P conneclor.lf the connectionsare good, substitutea known-good heatercontrol panel,and recheck.lf the symptom/ indicationgoes away, replacethe original heater control panel,I NO Repairany open in the wire{s)betweenthe heatercontrol panel and the recirculationcontrol motor.l 21-26 HeaterControlPowerand GroundCircuitsTroubleshooting 1 . C h e c kt h e N o . 1 4( 1 0 A ) f u s ei n t h e u n d e r - d a s h fuse/relaybox. 6. Checkfor continuitybetweenthe No. l3terminal of heatercontrol panelconnectorA (14P)and body g round. ls the f use OK? A (1ilP) HEATER CONTRoLPANELCONNEcToR YES-Go to step 2. N O - R e p l a c et h e f u s e ,a n d r e c h e c k . l 2. Disconnectheatercontrol panelconnectorA{'14P). 1 2 3 I 8 9 4 5 6 r0t, 1 l 12 .o 3. Turn the ignition switch oN (ll). 4. Measurethe voltage betweenthe No. l4terminal of heatercontrol panelconnectorA (14P)and body grouno. A {14P} PANELCONNECTOR HEATER CONTROL 2 3 7 8 I 1 0l , 4 11 12 14 BLK 5 6 14 BLK/YEL Wire side of temaleterminals Wire side of temaleterminals ls therc continuity? YES Checkfor loosewires or poor connectionsat healercontrol panel connectorA (14P).lfthe connectionsare good, substitutea known-good heatercontrol panel,and recheck.lf the symptom/ indicationgoes away, replacethe original heater control panel.l NO Checkfor an open in the wire betweenthe heatercontrol paneland body ground. lf the wire is O K ,c h e c kf o r p o o r g r o u n da t G 5 0 1I. ls there battery voltage? YES-Go to step 5. NO Repairopen in the wire betvveenthe No. 14 fuse in the under-dashfuse/relaybox and the heatercontrol panel.l Turn the ignitionswitch OFF. 21-27 Heatingand Air Conditioning CondenserFanCircuitTroubleshooting NOTE:lf neitherthe condenserfan nor the radiatorfan work, go to Radiatorand CondenserFansCommon CircuitTroubleshooting(seepage21-29). 1. Checkthe No. 1 (20A)fuse in the under-hood f u s e / r e l a yb o x ,a n d t h e N o . 1 4 ( 1 0 A ) f u s ei n t h e under-dashf use/relaybox. 4 . C o n n e ctth e N o . l a n d N o . 2 t e r m i n a l s o f t h e condenserfan relay 4P socketwith a jumper wire. CONDENSERFAN RELAYitP SOCKET Are the tuses OK? JUMPERWIRE YES-Go to step 2. NO Replacethe fuse(s),and recheck.t 2. Removethe condenserfan relayfrom the under-hoodfuse/relaybox, and test it ( s e ep a g e2 2 - 5 1 ) . Does the condenser lan tun? ls the relay OK? YES-Go to step 5. YES Go to step 3. NO Go to step8. NO- Replacethe condenserfan relay.l 5. Disconnectthe jumper wire. 3. Measurethe voltage betweenthe No, 2 terminal of the condenserfan relay 4P socketand body ground. CONDENSERFAN RELAYilP SOCKET 6. Turn the ignition switch ON (ll). 7. Measurethe voltage betweenthe No, 3 terminal of the condenserfan relay 4P socketand body ground. CONDENSER FAN FELAY4PSOCKET r-,_-l 1 2 | Flr \----1--rl IELK/YEL d, ls thete battery voltage? I YES-Go to step 4. ls there battery voltage? NO-Replace the under-hoodfuse/relaybox.l YES Replacethe under-hoodfuse/relaybox.t N O - R e p a i r o p e ni n t h e w i r e b e t w e e nt h e N o . 1 4 fuse in the under-dashfuse/relaybox and the c o n d e n s efra n r e l a y . l Disconnectthe jumper wire. 21-28 Radiatorand CondenserFans CommonCircuitTroubleshooting 9 . Disconnectthe condenserfan 2P connector, 1 0 .Checkfor continuitybetweenthe No. 1 terminal of the condenserfan relay 4P socketand the No. 2 terminal of the condenserfan 2P connector. CONDENSER FANRELAY4PSOCKET NOTE;lf both fans and the Ay'Ccompressorclutchdo not work when the Ay'Cswitch is on, go to Ay'CPressure Switch CircuitTroubleshooting(seepage 21-32l,. 1. Checkthe No. 1 {20A}and No. 4 (20A)fuses in the under-hoodfuse/relaybox, and the No. 14 (10A) fuse in the under-dashfuse/relaybox. Are the tuses OK? YES Go to steD2. NO Replacethe fuse(s),and recheck.l CONDENSERFAN 2P CONNECTOR Wire side of femaleterminals 2. Removethe condenserfan relavfrom the under-hoodf use/relaybox. 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ; . Is there continuity? 4. Measurethe voltage betweenthe No. 3 terminal of the condenserfan relay 4P socketand body ground. YES Go to step 11. NO- Repairopen in the wire betweenthe c o n d e n s efra n r e l a ya n d t h e c o n d e n s efra n , I '11. Checkfor continuitybetweenthe No. 1 terminal of the condenserfan 2P connectorand body ground. FAN2PCONNECTOR CONDENSER 2 1 -l r-, FANRELAY4PSOCKET CONDENSER 1 2 l f---r--- l,l,l lar-vverl oI BLK o ls there battery voltage? YES Go to step 5. Wire side of {emaleterminals ls there continuity? NO Repairopen in the wire betweenthe No. 14 fuse in the under-dashfuse/relaybox and the radiatorfan relay,and the condenserfan relay.l YES- Replacethe condenserfan motor.I 5. Turn the ignition switch OFF. NO Checkfor an open in the wire betweenthe condenserfan and body ground. lf the wire is oK, c h e c kf o r p o o rg r o u n da t G 3 0 1 . 1 l e c o n d e n s efra n r e l a y . 6 . R e i n s t a tl h 7 . M a k es u r et h e I V Cs w i t c hi s O F F . 8 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . (cont'd) 21-29 HeatingandAir Conditioning Radiatorand CondenserFans CommonCircuitTroubleshooting (cont'dl 9. Using a BackprobeSet, measurethe voltage betweenthe No. 6 terminal of ECN4 connectorB {24P)and body ground with the ECMconnectors connecteo. ECMCONNECTOR B {24P} CompressorClutchCircuit Troubleshooting 1. Checkthe No. 1 (20A)fuse in the under-hood f u s e / r e l a yb o x ,a n dt h e N o . 1 4 { 1 0 A ) f u s ei n t h e under-dashfuse/relaybox. Are the tuses OK? YES Go to step 2. NO Replacethe fuse(s),and recheck.I 2. Checkthe enginecoolanttemperature,the throttle positionsensor,and the idle speed (usethe Honda PGMTesterPGM-Fldata list if possible). ls the coolant temperaturc above nomal, the throttle position sensor rcading too high, or the idle speed too low? Wire side of femaleterminals ls there battery voltage? YES UDdatethe ECM if it does not have the latest so{tware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I NO Repairopen in the wire betweenthe radiator fan relay,the condenserfan relay and the ECM.t YES Troubleshootand repairthe causeof the high enginecoolanttemperature,high throttle positionsensor reading,or low idle speed.l NO-Go to step 3. 3. Removethe compressorclutchrelay from the under-hoodfuse/relaybox, and test it (seepage 225 1) . ls the relay OK? YES Go to step 4. NO Replacethe compressorclutch relay.I 4. Measurethe voltage betweenthe No. 2 terminal of the compressorclutch relay 4P socketand body ground. COMPfiESSON CLUTCHBELAY'P SOCKET ls there battery voltage? YES Go to step 5. NO Replacethe under-hoodfuse/relaybox.I 21-30 \ 5. Connectthe No. 1 and No. 2 terminalsof the compressorclutch relay 4P socketwith a jumper wire. COMPRESSORCLUTCHRELAY4P SOCKET L Turn the ignition switch OFF. 10. Reinstallthecompressorclutch relay. 11. l\4akesure the Ay'Cswitch is OFF. 1 2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) . JUMPERWIRE 13. Uslng the BackprobeSet, measurethe voltage betweenthe No. 18 termina!of ECI\4connector E {31P)and body ground with the ECMconnectors connected. ECMCONNECTOR E 131P} 2 3 t 4 5 6 1 1 4 1 5 16 Does the compressor clutch click ? 22 23 24 26 27 E 9 m 21 29 31 RED YES Go to step 6. N O - G o t o s t e p1 4 . 6. Disconnectthe jumper wire. Wire side of femaleterminals 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . ls there battery voltage? 8. Measurethe voltagebetweenthe No. 3 terminal of the compressorclutch relay 4P socketand body ground. COMPRESSOR CLUTCHRELAY4PSOCKET YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECIM,replacethe o r i g i n aE l CM.I NO Repairopen in the wire betweenthe c o m p r e s s ocr l u t c hr e l a ya n d t h e E C M . I 1 4 . D i s c o n n e ct h t e j u m p e rw i r e . 15. Disconnectthe compressorclutch lPconnector. ls there battery voltage? YES-Go to step 9. NO Repairopen in the wire betweenthe No. 1 4 fuse in the under-dashfuse/relaybox and the compressorclutch relay,I {cont'd) 21-31 Heatingand Air Conditioning Compressor ClutchCircuit Troubleshooting(cont'dl 16. Checkfor continuitybetweenthe No. lterminal of the compressorclutch relav 4P socketand the No. l terminal of the compressorclutch 1Pconneclor. COMPRESSON CLUTCHRELAY4PSOCKET A/C PressureSwitch Circuit Troubleshooting '1. Turn the ignition switch ON {ll). 2. Turn the blower switch on, and checkfor blower motor operatron. Does the blower motor run on all speeds? YES Go to step 3. NO Troubleshootthe blower motor circuit(see page21-20). 3. Turn the ignition switch OFF. 4. Disconnectheatercontrol panelconnectorA ('14P). COMPRESSORCLUTCH1P CONNECTOR Terminalside of male terminals ls therc continuity? YES-Check the compressorclutchclearance,the thermal protector,and the compressorclutchfield c o i l ( s e ep a g e2 1 - 4 8 ) . I 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 6. Measurethe voltage betweenthe No, 4 terminal of heatercontrol panelconnectorA {14P)and body ground. HEATER CONTROL PANELCONNECTOR A (I4P} NO-Repair open in the wire betweenthe compressorclutch relay and the compressor clutch.l Wire side of femaletermina's ls there battety voltage? YES Go to step 7. N O - G o t o s t e p9 . 1 . S t a nt h e e n g i n e . 21-32 8. Connectthe No.4terminal ofheatercontrol connectorA (14P)to body ground with a jumper wire, 11. Checkfor continuitybetweenthe No. 2 terminal of the A,/Cpressureswitch 2P connectorand the No. 9 terminal of under-dashfuse relav box connector F t12Pt. HEATER CONTROLPANELCONNECTOR A I14P} A/C PRESSURE SWITCH2PCONNECTOR W i r e s i d eo f f e m a l et e r m i n a l s BLU 2 3 7 8 I 4 r 0 l x 11 5 6 12 l 3 t 4 JUMPER WIBE UNDER.OASHFUSE/RELAYBOX CONNECTORF (12P) W i r es i d eo f f e n a l e l e r r r i n a l ' Wiresideoffemale terminals Does the A/C system come on? ls there continuity? YES Replacethe heatercontrol panel.! YES Go to step 12. NO Referto the multiplexcontrol system (see p a g e2 2 - 1 6 8 ) . 1 NO Repairopen in the wire betweenthe pressure under-dashfuse/relaybox and the A,,/C switch.I 9 . Usingthe BackprobeSet,connectthe No. 9 terminal of under-dashfuse/relaybox connector F ( 1 2 P t)o b o d y g r o u n dw i t h a j u m p e rw i r e . 1 2 . Checkfor continuitybetweenthe No. 1 and No. 2 terminalsof the A,/Cpressureswitch. A/C PRESSURE SWITCH BOXCONNECTOR F{12P} UNOER.DASH FUSE/RELAY 2 6 1 B g l r ot l 5 l2 BLU/WHT JUMPER WIRE Wire side of female terminals ls there continuity? Does the NC system come on? YES Go to step 10. NO- Referto the multiplexcontrol system (see p a g e2 2 - 1 6 8 ) . 1 '1. N O T EC : h e c kf o r m u l t i p l e xc o d e si n m o d e F o l l o w the troubleshooting{or any codesfound. lf no codesare found, subsititutea known-9ood m u l t i p l e xc o n t r o lu n i ta n d a E C Mo n e a t a t i m e . 1 0 . Disconnectthe Ay'Cpressureswitch 2P connector and under-dashfuse/relaybox connectorF { 12P). YES Repairopen in the wire betweenthe heater control panel and the A,/Cpressureswitch.l N O G o t o s t e p1 3 . '13.check for properAy'Csystem pressure. ls the pressure within specitications? YES Replacethe AilCpressureswitch.l NO Repairthe AilCpressureproblem.I 21-33 HeatingandAir Conditioning Air Mix ControlMotorTest 1. Disconnectthe 5P connectorfrom the air mix control motor. 2. Connectbatterypowertothe No. l terminal ofthe air mix control motor, and ground the No. 2 t e r m i n a l t; h e a i r m i x c o n t r o lm o t o rs h o u l dr u n ,a n d stop at Max Cool.lf it doesn't,reversethe connections;theair mix control motor should run, and stop at Max Hot. lf the air mix control motor does not run, remove it. then checkthe air mix control linkageand door for smooth movement. Air Mix ControlMotor Replacement 1 . Removethe under-dashfuse/relaybox (seepage 22-491. Disconnectthe 5P connector{A) from the air mix control motor (B).Removethe self-tappingscrews and the air mix control motor from the heaterunit. R e m o v et h e r o d ( C )f r o m t h e a r m ( D )o f t h e a i r m i x controi motor. ,.,:l' . lf the linkageand door move smoothly,replace the air mix control motor. . l f t h e l i n k a g eo r d o o r s t i c k o rb i n d ,r e p a i r t h e ma s needed. . lf the air mix control motor runs smoothly,go to step 3. AIRMIX CONTROLMOTOR 3 . Installthe motor in the reverseorder of removal. After installation,make surethe motor runs smoothly. 3 . Measurethe resistancebetweenthe No. 4 and No. 5 terminals.lt should be between2.1 k to 3 . 9k Q . 4 . Reconnectthe air mix control motor 5P connector, t h e nt u r n t h e i g n i t i o ns w i t c hO N { l l ) . Using the BackprobeSet, measurethe voltage betweenthe No. 3 and No. 4 terminals. Max Cool about 1V Max Hot about 4 V lf eitherthe resistanceor voltage readingsare not as specified,replacethe air mix cotrol motor. 21-34 \' Mode ControlMotor Test '1. Disconnectthe 10Pconnectorfrom the mode control motor. Mode ControlMotor Replacement 1 . R e m o v et h e E C M( s e ep a g e 1 1 - 4 ) . 2. Removethe relay mount bracketbolt, and move Connectbatterypower to the No. 1 terminal of the mode control motor, and groundthe No. 2 terminal;the mode control motor should run smoothly and stop at Defrost.lf it doesn't,reverse the connections;the mode control motor should run smoothly and stop at Vent.When the mode control motor stops running,disconnectbattery power immediately. the relaysout of the way. 3 . Disconnectthe 10Pconnector{A) from the mode control motor (B).Removethe self-tappingscrews and the mode control motor from the heaterunit. MODECONTROLMOTOR 3. lfthe mode control motor does not run in step 2, remove it, then checkthe mode control linkageand doors for smooth movement. 4 . lnstallthe motor in the reverseorder of removal. lvlakesure the pin on the linkageis properly engagedwith the motor. After installation.make sure the motor runs smoothly. . lf the linkageand doors move smoothly. replace the mode control motor. . l f t h e l i n k a g eo r d o o r s s t i c ko r b i n d ,r e p a i r t h e m as neeoeo. . lfthe mode control motor runs smoothly,go to step 4. 4 . Use a digital multimeterwith an output of 1 mA or lessat the 20 k Q range.With the mode control motor running as in step 2, checkfor continuity b e t w e e nt h e N o . 4 , 5 , 6 , 7 , 8 , a n d 9 t e r m i n a l sa n d t h e N o . 1 0t e r m i n a li n d i v i d u a l l yT.h e r es h o u l db e c o n t i n u i t yf o r a m o m e n ta t e a c ht e r m i n a la s t h e motor moves past each mode position. lf there is no continuityfor a moment at each terminal. replacethe mode control motor. 21-35 HeatingandAir Conditioning RecirculationControlMotor Test RecirculationControlMotor Replacement I 1. Disconnectthe 5P connectorfrom the recirculation control motor. 1 . R e m o v et h e E C M( s e ep a g e1 1 - 4 ) . Incorrectlyapplying power and ground to the recirculationcontrol motor will damge it. Follow the instructionscarefullv. 2. Connectbattervoower to the No. 5 terminal ofthe recirculationcontrol motor, and ground the No. 1 and No. 2 terminals;the recirculationcontrol motor should run smoothly.To avoid damagingthe recirculationcontrol motor, do not reversepower and ground. Disconnectthe No. 1 or No. 2 terminalsfrom ground;the recirculationcontrol motor should stop at Freshor Recirculate.Don't cyclethe recirculationcontrol motor {or a long time. Removethe relay mount bracketbolt.and move the relaysout of the way, Disconnectthe 5P connector(A)from the recirculationcontrol motor (B),Removethe selftapping screwsand the recirculationcontrol motor from the blower unit. RECIRCULATION CONTROL MOTOR Installthe motor in the reverseorder of removal. Make sure the pin on the motor is properly engagedwith the linkage.After installation.make sure the motor runs smoothly. lf the recirculationcontrol motor does not run in step 2, remove it, then checkthe recirculation control linkageand doors for smooth movement. . lfthe linkageand doors move smoothly,replace the recirculationcontrol motor. . l f t h e l i n k a g e o r d o o r s s t i c k obr i n d ,r e p a i r t h e m as neeoeo. 21-36 \ EvaporatorTemperatureSensor Replacement 1 . Removethe driver'sdashboardlower cover (see page 20-59)and the under cover (seepage 20-60). Removethe under-dashfuse/relaybox (seepage 22-491. EvaporatorTemperatureSensor Test l. Dip the sensorin ice water, and measurethe resistancebetweenits terminals EVAPORATOR TEMPERATURE SENSOR Disconnectthe 2P connector(A)from the evaporatortemperaturesensor(B),then remove the connectorclip (C).Removethe self-tapping screw,and carefullypull out the evaporator temperature. Terminalside ol male terminals 2 . Then pour hot water on the sensor,and check{or a changein resistance. 3 . Comparethe resistancereadingswith the specificationsshown in the graph;the resistance should be within the specifications 4. Installthe sensorin the reverseorder of removal, RESISTANCE k9 t0 32 0 50 10 68 20 86 'F 30'c TEMPERATURE 21-37 HeatingandAir Gonditioning PowerTransistorTest 1. Disconnectthe 4P connectorfrom the power Iranslslor. 2, Measurethe resistancebetweenthe No. 1 and No. 2 terminalsof the power transistor.lt should be '1.4 1 . 5k Q . about . lf the resistanceiswithln the specifications, go to step 3. . lf the resistanceis notwithin the specifications, replacethe power transistor. a HeaterControlPaneland Push Switch AssemblyRemovaland Installation 1 . Removethe centerpanel (seepage 20-62). Removethe dials (A),then removethe self-tapping screwsand the heatercontrol panel (B)from the centerpanel (Cl. Removethe self-tappingscrews and the push switch assembly(D)from the center panel. POWERTRANSISTOB C a r e f u l l yr e l e a s et h e l o c kt a b o n t h e N o . 4 t e r m i n a l (BLUI/EL)(A) in the 4P connector,then removethe terminaa l n d i n s u l a t ei t f r o m b o d y g r o u n d . \ 3 . lnstallthe control panel and push switch assembly in the reverseorder of removal.After installation, operatethe control panel controlsto see whether it worKspropeny. functionto confirm that 4 . Runthe self-diagnosis there are no problemsin the system (seepage218). (To112 power o w e rssource 2V p o u r c eo on n vvehicle) ehicle) Reconnectthe 4P connectorto the power transistor. S u p p l y1 2v o l t st o t h e N o . 4 c a v i t yw i t h a j u m p e r wire. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e b l o w e rm o t o r r u n s . . lf the blower motor does not run, replacethe power rranstsror. . l f t h e b l o w e rm o t o r r u n s , t h ep o w e r t r a n s i s t o r i s oK. 21-38 Dustand PollenFilterReplacement The dust and pollenfilters should be replacedevery 3 0 , 0 0 0m i l e s( 4 8 . 0 0 0 k m ) o r 2 4 m o n t h sw h i c h e v e r comes first. Replacethe filters more often if the air flow i s l e s st h a n u s u a l . 1. Openthe glove box. Removeboth glove box stops, then let the glove box hang down (seepage 20 63). 2 . R e m o v et h e f i l t e rl i d ( A ) f r o mt h e b l o w e ru n i t ,t h e n p u l l o u t t h e f i r s td u s ta n d p o l l e nf i l t e r( B ) .S l i d et h e secondfilter to the left,and pull it out. BlowerUnit Removaland lnstallation For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautionsand procedures(seepage 23-14) in the SRSsectionbeforeperforming repairsor service. 1. Make sure you havethe anti-theftcode for the radio, then write down the frequenciesfor the preset buttons. 2. Disconnectthe batterynegativecable,and wait 3 minutesbefore beginningworK. 3. Removethe right kick panel (see page 20-50), passenger'sdashboardlower cover,and the glove box {seepage 20-63). 4. Cut the plasticcross bracein the glove box opening with diagonalcuttersin the area shown. Remove and discardthe plasticcross brace, Removethe filter {A) from the housing (B),and replacethe filter. Cut heare. 4. Installthe filters in the reverseorder of removal. {cont'd) 21-39 Heatingand Air Gonditioning Blower Unit Removaland Installation{cont'd} Removethe steeringhangerbeam bracketcover from the right side of the glove box opening,then removethe bolts and the olove box frame. 10. Disconnecttheconnector{A) from the recirculation control motor, then removethe wire harnessclip {B).Removethe mounting bolts,the mounting nuts a n d t h e b l o w e ru n i t ( C ) . Removethe ECM(seepage 11-4). 1 . Removethe EPScontrol unit (seepage 17-67). 6 x 1 . 0m m I 9.8N.m(1.0kgt.m, 7.2tbt.ftl 8 . Disconnectand removethe PGM-Flmain relays and bracketassembly,then removethe ECM bracket. 9 . Disconnectthe connectors{A) from the blower motor and the power transistor,then removethe wire harnessclips (B)and the connectors(C). Removethe self-tappingscrewsand the bracket(D). A 6x1.0mm 9.8 N.m (1.0kgf.m, ?.2 tbf.ft) 1 1 .I n s t a l l l h eu n i t i n t h e r e v e r s eo r d e ro f r e m o v a l . M a k es u r et h a tt h e r ei s n o a i r l e a k a g e . Reconnectthe negativebatteryterminal. '13. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n procedure { s e ep a g e1 1 - 1 3 9 ) . 1 4 . Enterthe anti-theftcode for the radio,then enter the customer'sradio station presets. 21-40 \ Blower Unit ComponentsReplacement Nole these items when overhaulingthe blower unit; ' The recirculationcontrol motor (A),the power transistor(B),the blower motor (C),and the dust and pollenfiltefs (D) can be replacedwithout removingthe blower unit. . Beforereassembly,make surethatthe recirculationcontrol linkageand doors move smoothly. . After reassembly,make surethe recirculationcontrol motorruns smoothly (seepage 2j-36). A 21-41 Heatingand Air Gonditioning a EvaporatorCoreReplacement 1 . Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage 21-53). 5. Carefullypull out the evaporatorcore without bendingthe pipes. Removethe bolt, then disconnectthe suctionline (A) and the receiverline (B)from the evaporator core. 6x10mm 9.8N.m(1.0kgt.m,7.2lbf.ft) Removethe blower unit (seepage 21-39). Removethe self-tappingscrewsand the expansion valve cover. 21-42 6 . Installthecore in the reverseorder of removal,and note these items. . lfyou're installinga new evaporatorcore, add r e f r i g e r a not i l ( K E l H l NS P - ] 0 )( s e ep a g e2 1 - 6 ) . . Replacethe O-ringswith new ones at eachfitting, and apply a thin coat of refrigerantoil before installingthem. Be sure to use the correctO-rings f o r H F C - 1 3 4(aR - ' 1 3 4 tao) a v o i dl e a k a g e . . l m m e d i a t e l y a f t eurs i n g t h eo i l , r e i n s t a l l t h e c a p on the container,and seal it to avoid moisture absorotion. . Do not spill the refrigerantoil on the vehicle;it may damagethe paint. lf the refrigerantoil contactsthe paint,wash it off immediately. . Chargethe system (seepage 21-55). HeaterUnit/CoreReplacement SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23'13),and precautionsand procedures(seepage 23-14)in the SRS sectionbefore performingrepairsor service. 1. Make sure you have the anti-theftcode forthe radio, then write down the freouenciesfor the radio's Dresetbuttons. 6. Slidethe hose clamps (A) back,then d isconnectthe inlet heaterhose (B)and the outlet heaterhose (C) from the heatercore. Enginecoolantwill run out when the hosesare disconnected;drain it into a clean drip pan. Be sure not to let coolantspill on the electricalpartsor the paintedsurfaces.lf any coolantspills,rinse it off immediately. Disconnectthe negativecablefrom the battery, Disconnectthe suctionand receiverlinesfrom the evaporator core (see page 21-42). 4 . From underthe hood, open the cableclamp (A), then disconnectthe heatervalve cable (B)from the heatervalve arm (C).Turn the heatervalve arm to the fully openedpositionas shown 7 . Removethe bolt and the heatervalve,then remove the mounting nut from the heaterunit. Takecare not to damageor bend the fuel lines and the brake lines,etc. W h e nt h e e n g i n ei s c o o l ,d r a i nt h e e n g i n ec o o l a n t from the radiator(seepage 10-6). 8 x 1.25mm 12 N.m (1.2kgf.m,8.7lbf.ft) (cont'd) 21-43 Heatingand Air Conditioning HeaterUnit/CoreReplacement(cont'd) 8. Removethe dashboard{seepage 20-66). 1 1 . R e m o v et h e m o u n t i n gb o l t s ,t h e m o u n t i n gn u t s , and the heaterunit. 9. Disconnecttheconnectors(A) from the blower motor, the recirculationcontrol motor, the mode control motor, and the power transistor,then removethe wire harnessclips (B)and the connector(C).Removethe self-tappingscrewsand the bracket(D). 7 t , 5 x 1 . 0m m 9.8 N.m 11.0kgl m, 7.2 tbf.ftl 12. Removethe self-tappingscrewsand the expansion 1 0 ,Disconnectthe connectors(A) from the evaporator temperaturesensorand the air mix control motor, then removethe wire harnessclips (B) and the connector(C).Removethe self-tappingscrew and the cover (D).Disconnectthe heatervalve cable (E). valve cover (A).Carefullypull out the evaporator core (B)so you don't bendthe inlet and outlet pipes. Removethe grommet (C),then removethe selftapping screwsand the flange cover (D).Bemove the self-tappingscrewsand the pipe cover (E),then carefullypull out the heatercore (F)so you don't bend the inlet and outlet oioes. @ 21-44 13. Installthe heatercore and the evaporatorcore in the reverseorder of removal. 14. Installthe heaterunit in the reverseorder of removal,and note these items: . Do not interchangethe inlet and outlet heater hoses,and installthe hoseclamps securely. . Refillthecooling systemwith engine coolant(see page 10-6). . Adjust the heatervalve cable (see page2'l-461. . Make sure that there is no coolantleakage. . Make sure that there is no air leakage. . Referto evaporatorcore replacement{seestep 6 o n p a g e2 1 - 4 2 ) . . Do the enginecontrol module (ECl\4)idle learn p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) . . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationDresets. 21-45 Heatingand Air Conditioning HeaterValveCableAdjustment 1 . F r o mu n d e r t h eh o o d ,o p e nt h e c a b l ec l a m p{ A ) , then disconnectthe heatervalve cable (B)from the heatervalve arm {C). 5, From under the hood,turn the heatervalve arm {C) to the fully closedpositionas shown, and hold it. Attachthe heatervalve cable (B)to the heatervalve a r m ,a n d g e n t l yp u l l o n t h e h e a t e rv a l v ec a b l e housingto take up any slack,then installthe heater v a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) . .'.-:',, - " l l ...... t From under the dash,disconnectthe heatervalve c a b l eh o u s i n gf r o m t h e c a b l ec l a m p( A ) ,a n d disconnectthe heatervalve cable (B)from the air m i x c o n t r o l i n k a g e{ C ) . \ t.- l , \'r2t' ' ''' ' ::"' Set the temperaturecontrol dial on Max Cool with the ignition switch ON (ll). Attachthe heatervalve cable (B)to the air mix control linkage(C)as shown above,then snap the h e a t e rv a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) . 21-46 CompressorReplacement 1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er,u n t h e engineat idle speed,and let the air conditioning work for a few minutes,then shut the engine off. 8. Removethe mounting bolts and the compressor. 2. Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the radio's presetbuttons. 3. Disconnectthe negativecablefrom the battery. 4. Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage 21-53). 5. Removethe alternator(seepage 4-29). 6. Removethe Ay'Ccondenserfan assembly(seepage 10-10). 7. Disconnectthecompressorclutchconnector(A), removethe bolts,then disconnectthe suction line ( B )a n d t h e d i s c h a r g el i n e( C ) f r o mt h e c o m p r e s s o r . Plug or cap the lines immediatelyafter disconnectingthem to avoid moistureand dust contamination. 6 x '1.0mm 9.8 N.m 11.0kgt.m, 7.2 tbl.ttl u1/ ( o 8 x 1 . 2 5m m 22 N.m12.2kgf.m. 9 . I n s t a l l t h ec o m p r e s s oirn t h e r e v e r s eo r d e ro f removal,and note these items: . Beforeinstallingthe new compressor,checkfor m e t a lo r o t h e rc o n t a m i n a t i o inn t h e l i n e .R e p l a c e any contaminatedparts. . lf you're installinga newcompressor,you must calculatethe amount of refrigerantoil to be removedfrom it (seepage 21-6). . Replacethe O-ringswith new ones at each fitting, and apply a thin coat of refrigerantoil before installingthem. Be sure to use the correctO-rings f o r H F C - 1 3 4{aR - 1 3 4 at o ) a v o i dl e a k a g e , . U s er e f r i g e r a not i l ( K E l H l NS P - ' 1 0f o ) r HFC-134a K E I H I Ns p i r a lt y p e c o m p r e s s oor n l y . . To avoid contaminatlon,do not returnthe oilto the containeronce dispensed,and never mix it with other refrigerantoils. . l m m e d i a t e l ya f t e ru s i n gt h e o i l , r e i n s t a l l t h ec a p on the container,and seal it to avoid moisture absorption. . Do not spill the refrigerantoil on the vehicle;it may damagethe paint. lf the refrlgerantoil contactsthe paint,wash it off immediately. . Chargethe system (seepage 21-55). . D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n p r o c e d u r e( s e ep a g e1 1 - ' 1 3 9 ) . . Enterthe antitheft code for the radio,then enter the customer'sradio station presets. 21-47 HeatingandAir Gonditioning a CompressorClutchCheck 1 . Checkthe armatureplatefor discoloration,peeling, or other damage.lf there is damage,replacethe clutch set (seepage 21-49), Checkthe rotor pulley bearingplay and drag by rotatingthe rotor pulley by hand.Beplacethe clutchset with a new one if it is noisy or has excessiveplay/drag(seepage 21-49). 4. Releasethe field coil connectorf rom the holder, then disconnectit. Checkthe thermal protectorfor continuity.lf there is no continuity,replacethe t h e r m a lp r o t e c t o (r s e ep a g e2 1 - 5 1 ) . NOTE:The thermal Drotectorwill have no . hen c o n t i n u i t ya b o v e2 5 2 t o 2 7 0 " F\ 1 2 2 l o 1 3 2 ' C )W t h et e m p e r a t u r e d r o p sb e l o w2 4 1t o 2 1 9 ' F( 1 1 6t o 104'C),the thermal protectorwill have continuity. ,\. Measurethe clearancebetweenthe rotor pulley (A) and the armatureplate (B)all the way around.lf the clearanceis not within specifiedlimits, removethe armatureplate (seepage 21-49)and add or remove shims as neededto increaseor decreaseclearance. Checkresistanceof the field coil. lf resistanceis not within specifications,replacethe field coil ( s e ep a g e2 1 - 4 9 ) . FieldCoil Resistance: 3.05 3.35ohmsat68"F Clearance: 0.510.15 mm {0.02010.006in.) N O T ET : h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s : 0 . 1m m . 0 . 2m m , 0 . 4m m , a n d0 . 5m m . 21-48 t20"c) Compressor ClutchOverhaul Special Tool Required A,/Cclutch holder,Robinair10204.Kent-MooreJ37872, or HondaTool and EquipmentKMT-J33939, c o m m e r c i a l la yvailable 1 . R e m o v et h e c e n t e rn u t ( A )w h i l e h o l d i n gt h e armatureplatewith a commerciallyavailableA,/C c l u t c hh o l d e r( B ) . 1 7 . 6N . m {1.8kgf.m, 13 tbt.ft) 3. lf you are replacingthe field coil, removethe snap ring (A) with snap ring pliers,then removethe rotor pulley (B).Be careful not to damagethe rotor pulley or tne compressor. \ot -@ /@h" .ffi Removethe armatureplate (A) and shim(s)(B), taking care not to losethe shim(s).lf the clutch needsadjustment,increaseor decreasethe number and thicknessof shims as necessary,then reinstallthearmatureDlate,and recheckits clearance(see page21-481. 4. Removethe bolt and holder (A).then disconnect the field coil connector(B).Loosenthe clamp screw (C)to iree the field coil wire. Removethe snap ring { D ) w i t hs n a pr i n g p l i e r s t, h e n r e m o v et h e f i e l dc o i l (E).Be careful not to damagethe field coil or the comoressor. N O T ET : h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s : 0 . 1 m m , 0 . 2 m m , 0 . 4 m m , a n d 0 . 5m m . 9-=-g 7.4 N.m (0.75kgf m, 5 tbf.ft) ---------------- "\) (cont'd) 21-49 HeatingandAir Gonditioning CompressorClutchOverhaul(cont'd) 5. Reassemblethe clutch in the reverseorder of disassembly,and note these items: . I n s t a l l t h ef i e l dc o i lw i t h t h e w i r e s i d ef a c i n g down, and align the boss on the field coil with the h o l ei n t h e c o m p r e s s o r . . Cleanthe rotor pulley and compressorsliding surfaceswith contactcleaneror other non-petroleumsolvent. . I n s t a l l n e w s n a pr i n g s ,n o t et h e i n s t a l l a t i o n direction,and make surethey are fully seatedin the groove. . Make sure that the rotor pulleyturns smoothly after it's reassembled, . R o u t ea n d c l a m pt h e w i r e sp r o p e r l yo r t h e y c a n be damagedby the rotor pulley. 21-50 CompressorThermalProtector Replacement 1. Removethe bolt,the ground terminal (A),and the holder (B).Disconnectthe field coil connector(C). then removethe thermal protector(D). CompressorReliefValve Replacement 1 . Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage 21-53). 2 . Removethe reliefvalve (A) and the O-ring (B).Plug the openingto keepforeign mafterfrom entering the system and the compressoroil from running out. 7.4 N.m (0.75kgf.m, 5 rbf.ftl A 9,8 N.m (1.0kgf m,7.2lbf.ft) Replacethe thermal protector(A)with a new one, and apply siliconesealant(B)to the bottom of the thermal Drotector. Clean the mating surfaces. 4 . Installa new O-ringon the reliefvalve, and apply a thin coat of refrigerantoil to the O-ring. Removethe plug, and installand tightenthe relief valve. Chargethe system (seepage21-55). A 3. lnstall in the reverse order of removal. 21-51 Heatingand Air Conditioning GondenserReplacement 1 . Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage 21-53). Removethe front bumper {seepage 20-85). Removethe bolts,then disconnectthe discharge line (A) and the condenserline (B)from the condenser.Plug or cap the lines immediatelyafter disconnectingthem to avoid moistureand dust conlamtnaflon. 4, Removethe mounting bolts,then removethe condenserby lifting it up. Be carefulnot to damage the radiatoo r r t h e c o n d e n s efri n s w h e n r e m o v i n o the condenser. 6 x '1.0mm 9.8 N.m ('1.0kgf.m, 7.2 tbl.ftl t t- -"'. f, -li :.--\ ---- .:)- - -' 5 . l n s t a l l t h ec o n d e n s eirn t h e r e v e r s eo r d e ro f removal,and note these items. 6x1.0mm 9.8 N.m ('1.0kgf.m,7.2lbf.ft) ,t\ 6x1.0mm 9.8 N.m (1.0kgt.m.7.2lbf.ft) 21-52 . l f y o u ' r ei n s t a l l i n ga n e w c o n d e n s e ra,d d r e f r i g e r a not i l ( K E l H l NS P -1 0 )l s e ep a g e2 1 ' 6 ) . . Replacethe O-ringswith new ones at eachfitting, and apply a thin coat of refrigerantoil before installingthem. Be sure to usethe correctO-rings t ov o i dl e a k a g e . f o r H F C - 1 3 4(aR - ' 1 3 4 a ) a . lmmediatelyafter using the oil, reinstallthecap on the container,and seal it to avoid moisture absorption. . D o n o t s p i l l t h er e f r i g e r a not i l o n t h e v e h i c l e ; i t may damagethe paint.lf the refrigerantoil contactsthe paint,wash it off immediately. . Be carefulnot to damagethe radiatoror the condenserfins when installingthe condenser. . Chargethe system (seepage 21-55). RefrigerantRecovery Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose.or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor 1. Connecta R-134arefrigerantrecovery/recycling/ chargingstation{A) to the high-pressureservice port (B)and the low-pressureserviceport (C),as shown, following the equipmentmanufacturer's instructions. 1!l Use only serviceequipmentthat is U.L.-listedand is certifiedto meet the requirementsof SAE J2210to r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g system. lf accidentalsystemdischargeoccurs,ventilatethe work area before resumingservice -'', r: i - '=i -: t: ( - r Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricant manufacturers. lvleasurethe amount of refrigerantoil removed from the Ay'Csystem after the recoveryprocessis completed.Be sure to put the same amount of new refrigerantoil backinto the Ay'Csystem before chargrng. 21-53 Heatingand Air Conditioning SystemEvacuation . Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throat. . Be carefulwhen connectingserviceequipment. . Do not breatherefrigerantor vapor. Use only serviceequipmentthat is U.L.-listedand is certifiedto meet the requirementsof SAE J2210to r e m o v eH F C - 1 3 4(aR - 1 3 4 a ) f r o m t h e a i rc o n d i t i o n i n q system. 2. Connecta R-134arefrigerantrecovery/recycling/ chargingstation(A)to the high-pressureservice pon (B)and the low-pressureserviceport (C),as shown,following the equipmentmanufacturer's instructions.Evacuatethe system. -i - r4.t lf accidentalsystem dischargeoccurs,ventilatethe work area before resumingservice. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers. 1. When an Ay'Csystem has been openedto the atmosphere,such as during installationor repair,it must be evacuatedusing a R-134arefrigerant recovery/recycling/charging station(lf the system has been open for severaldays,the receiver/dryer should be replaced,and the system should be evacuatedfor severalhours.) lf the low-pressuredoes not reachmore than 93.3 k P a{ 7 0 0m m H g ,2 7 . 6i n . H g )i n 1 5 m i n u t e st,h e r ei s probablya leak in the system.Partiallychargethe system,and checkfor leaks(seestep 3 on page 2156). 21-54 SystemCharging 2 . Evacuatethe system(seepage 21'54). Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor, 3 . Add the same amount of new refrigerantoil to the systemthat was removedduring recovery.Use only KEIHINSP-10refrigerantoil. 4 . Chargethe system with the specifiedamount of dn di s U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . ' l i s t e a certifiedto meet the requirementsof SAEJ2210to r e m o v eH F C - 1 3 4{aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g system. lf accidentalsystem dischargeoccurs,ventilatethe work area before resumingservice Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricant manufacturers. R-134arefrigerant.Do not overchargethe system; the compressorwill be damaged. Selectthe appropriateunits of measurefor your refrigerantchargingstation. Refrigerant capacity: 500 to 550 g 0.50to 0.55 kg 1 . 1 0t o 1 . 2 1l b s 17.6to 19.4oz Checkfor refrigerantleaks(seepage 21'56). 1. Connecta R-134arefrigerantrecovery/recycling/ c h a r g i n gs t a t i o n( A )t o t h e h i g h - p r e s s u rsee r v i c e pon (B)and the low-pressureserviceport {C),as shown, following the equipmentmanufacturer's instructions. Checkfor system performance(seepage 21-58). 21-55 HeatingandAir Conditioning RefrigerantLeakTest Special Tool Required Leakdetector,HondaTool and EquipmentYGK-H-10PM c o m m e r c i a l la vvailable 1. Connecta R-134arefrigerantrecovery/recycling/ chargingstation(A)to the high-pressureservice port (B)and the low-pressureserviceport (C),as shown, following the equipmentmanufacturer's anstructions. Compressedair mixed with R-134aforms a combustiblevapor. The vapor can burn or explodecausingserious injury. Neverusecompressed airto pressure test R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r conditioningsystem. A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor Use only serviceequipmentthat is U.L.-listedand is certiifiedto meet the requirementsof SAE J2210to r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g system. lf accidentalsystem dischargeoccurs,ventilatethe work area before resumingservice. R - 1 3 4 as e r v i c ee q u i p m e n o t r v e h i c l ea i r c o n d i t i o n i n g systemsshould not be pressuretestedor leaktested with compressedair. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers. Open the high pressurevalve to chargethe system to the specifiedcapacity,then closethe supply valve,and removethe chargingsystem couplers. Selectthe appropriateunits of measurefor your refrigerantchargingstation. Refrigerant capacity: 500 to 550 g 0.50to 0.55kg 1 . 1 0t o 1 . 2 1l b s 17.6to 19.4oz 3 . Checkthe systemfor leaksusing a R-134a refrigerantleak detectorwith an accuracyof 14 g (0.5oz) per year or better. lf you find leaksthat requirethe systemto be opened(to repair or replacehoses,fittings,etc.), recoverthe system. After checkingand repairingleaks,evacuatethe system. 21-56 A/C SystemTests Pressure Test Test results (high) Discharge pressure abnormallyhigh svmotom3 pressure Afterstoppingcompressor, to dropsquickly,andthencontinues Beduced or no airflow through condenser hot. Lineto condenser is excessively DGaUSe Air in system Cloggedcondenser or radiator fins or radiatorfan not Condenser Restrictedflow of refrigerantin discharge pressure Highand low pressures arebalanced . Faultycompressor Discharge valve Low soonafterstoppingcompressor, . Faultvcomoressor seal sideis hioherthannormal. valve Faultyexpansion Outletof expansionvalve is not gaugeindicates Moisturein system frosted,low pressure (low) Suction pressure low abnormally Suctionpressure high abnormally Expansion valveis not frosted,and lineis not cold.Low low-pressure pressure gaugeindicates vacuum, is low,andthe Frozenevaporator Discharge temperature air flow from vents is restricted. Exoansion valveis frosted. Receivetdryer outletis cool,and inlet Cloggedreceiver/dryer is warm (shouldbe warm during ooeralton), Low pressure hoseandcheckjointare E x p a n s i o nv a l v e o p e n t o o l o n g around coolerthanthetemperature evaoorator, in system refrigerant Excessive is loweredwhen Suctionpressure ..nrlenser is cooled bv water. areequalized Highand low pressure is stopped, assoonasthecompressor while andbothgaugesfluctuate Suctionand dascharge pressures abnormallv hioh Suctionand pressure discharge abnormally low leaks Fefrigerant ' Frozenexpansion valve (Moisturein system) . Faultyexpansion valve Faultygasket valve Faultyhigh pressure Foreignpaniclestuckin high or radiator Reduced airflow throughcondenser. . Cloggedcondenser fins ' Condenser or radiatorfan not workinoorooerlv Cloggedor kinkedlow-pressure hoseand metalend Low-pressure hoseoarts areasarecoolerthanevaoorator, valve C l o g g e d h i g h - p r e s s u r el i n e Temperature aroundexpansion is too low comparedwith thataround :omoressor clulchis dirtv. lomoressorbolt(s)aredirtv. ; o m D r e s s o ro a s k e t i s w e t w i t h o i l . :omoressor shaftsealleakinq no aroundbolt(s) iet no Recover,evacuate(seepage21-54), and rechargewith specifiedamount {seeoaoe21 55). Clean Checkfan voltageand rpm. Checkfan direction. restricted lines. Replace the compressor. Beplace . Replace valve. the expansion . Recover,evacuatefor at least 30 minutes,and rechargewith sDecified amount. Recover,evacuatefor at least with 30 minutes,and recharge amount. specified valve. the expansion Beplace Runthe fan with compressoroff, then checkevaooratottemoeraturesensor. eanor reolace, Replacereceaver/dryer. Bepairor replace. Recover,evacuate,and rechargewith qnp.ifie.lamo'rnr Replace the compressor. Clean Checkvoltageand fan rpm. Checkfan direction. Repairor replace. Repairor replace, Reolace the comDressor, Tiohtenbolt{s)ot reolacecomDressor, acethe comoressor. (cont'd) 21-57 Heatingand Air Conditioning A/C SystemTests(cont'd) PerformanceTest ' Compressedair mixed with R-134aforms a combustiblevapor. . T h e v a p o rc a n b u r n o r e x p l o d ec a u s i n gs e r i o u s Injury. . Never use compressedair to pressuretest R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r conditioning systems. Open the glove box. Removeboth glove box stops, then let the glove box hang down (seepage 20-63). 4 . Inserta thermometer(A) in the centervent, and placeanotherthermometer{B) nearthe blower unit. Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throar. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor. The performancetest will help determineif the air conditionersystem is operatingwithin specifications. Use only serviceequipmentthat is U.L.-listedand is cenified to meet the requirementsof SAE J2210to r e m o v eH F C - 1 3 4(aR - 1 3 4 a l f r o m t h e a i rc o n d i t i o n i n g system. lf accidentalsystem dischargeoccurs,ventilatethe work area before resumingservice R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r c o n d i t i o n i n g systemsshould not be pressuretestedor leaktested with compressedair. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers. 1 . Connecta R-134arefrigerantrecover/recycling/ chargingstationto the high-pressureserviceport and the low-pressureserviceport, following the equipmentmanufacturer'sinstructions. D e t e r m i n et h e r e l a t i v eh u m i d i t ya n d a i r Iemperarure. 21-58 Test conditions: . . . . Avoid direct sunlight. Open the hood. Open the front doors. Sel the temperaturecontrol dial on Max Cool,the mode control dial on Vent,and the recirculation control switch on Recirculate. . Turn the A,/Cswitch on and the fan switch on Max. . R u nt h e e n g i n ea t 7 5 0 r p m . . N o d r i v e ro r p a s s e n g e risn v e h i c l e . A f t e r r u n n i n gt h e a i r c o n d i t i o n i n fgo r I 0 m i n u t e s underthe above test conditjons,read the delivery temperaturefrom the thermometerin the center vent, the intaketemperaturenear the blower unit, and the high and low system pressurefrom the Ay'C g au g e s . 7. To completethe charts: . . . . . . . . M a r k t h ed e l i v e r y t e m p e r a t u a r el o n gt h e v e r t i c a l i n e . Mark the intaketemperature(ambientair temperature)along the bottom line. Draw a line straightup from the air temperatureto the humidity. M a r ka p o i n t 1 0% a b o v ea n d 1 0% b e l o w t h eh u m i d i t yl e v e l . From each point. drawa horizontalline acrossthe deliverytemperature. The delivervtemperatureshould fall betweenthetwo lines Completethe low-sidepressuretest and high-sidepressuretest in the same way. Anv measurementsoutsidethe line may indicatethe needfor further inspection. kPa (ksl{cm') Lpsrl 2500[25) _ 360l {kgflcm') Lpsil 600 {6t 80 yo a0 0/" tssl 2000 (201 1280 HUMIDITY LEVEL 30 9o fcl 1500{1s} ,21o) 30% 80% 1000(101 :1401 500 {5) 171l DELIVERY PRESSURE 100 {11 h4l INTAKE PRESSURE OELIVERY TEMPERATURE 68 t20l I I 86 77 t30) t25l INTAKETEMPEBATURE I 95 (35) 104 {40) .F {'cl 21-59