Accessory Application Publications No. … Application Publications No. Issue Date AIR CONDITIONER...

2002 American Honda Motor Co., Inc. – All Rights Reserved AII 24158 (0209) 8000X-S5D-C22 1 of 24

Accessory Application Publications No.

Issue DateAIR CONDITIONER CIVIC2- AND 4-DOOR

SEP 2002

AII 24158

INSTALLATIONINSTRUCTIONS

What’s New

The installation instructions for the 2003 CivicA/C are the same as the 2002 model. However,the A/C kit numbers are different because ofimprovements to the wire length on thecompressor:

• 80000-S5D-A22 for U.S.

• 80000-S5D-C22 for Canada

TOOLS AND SUPPLIES REQUIREDDuct tapeHacksaw bladeTrim clip removerOpen-end wrench setScrewdriversSocket wrench setTorque wrenchTension gaugeRefrigerant oil (R-12 mineral oil or R-134a PAG oil)Fender, floor, and seat coversHFC-134a refrigerant recovery/recycling/charging

stationGlovesEye protection (face shield or safety goggles)Electronic leak detector

NOTICE

� Use only HFC-134a in this system; do notuse CFC 12 (Freon); do not install partsdesigned for use in a CFC system.

� Use a charging station. A/C chargingstations and refrigerant recovery/recyclingstations minimize the release of CFCs andHFCs to the atmosphere. Use them for all A/Ccharging and service work according to themanufacturers’ instructions.

� Do not overcharge. This system requiresonly the amount of HFC-134a refrigerantshown below. If you overcharge the system,the engine and the A/C will malfunction.

500 to 550 grams

0.50 to 0.55 kilograms

1.1 to 1.2 pounds

17.6 to 19.4 ounces

INSTALLATION

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NOTE:

� Make sure you have the anti-theft code forthe audio system.

� Write down the customer’s radio stationpresets; the radio memory will be erasedwhen you disconnect the battery.

� Make sure you install the right part. Use theillustrations on pages 2 and 3 as a guide tocheck the parts before you install them.

� Don’t remove plugs and caps from fittingsuntil the parts are ready to connect. Thiswill keep out moisture and dirt which couldcause wear and damage.

During Installation:� Before you connect any line or hose,

check and lube its O-ring. Make sure theO-ring is on the fitting, put a few drops ofrefrigerant oil on the O-ring, then connect thefitting.

� You may use either type of refrigerant oil tolubricate O-rings and fittings.

� If you add or replace refrigerant oil in thesystem, use only this PAG oil: Sanden SP-10,P/N 38897-P13-A01.

� Route and secure the lines and hosesproperly; maintain clearance between themand surrounding parts.

� Use two wrenches to tighten or loosenfittings; hold one fitting in place while youtighten the other one against it.

NOTICE Don’t overtighten; you coulddamage the fittings. Before you tighten afitting, check the torque listed for it. If leaksare caused by faulty O-rings, overtighteningthe fitting won’t help.

� Before you connect each electricalconnector, check its terminals. Make surethe terminals aren’t bent or out of place.

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Group A

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1. Disconnect the battery.

Remove thenegative cablefrom the battery.

2. Remove the driver’s dashboard lower cover and the under-dash fuse/relay box.


3. Remove the passenger’s dashboard lower cover and the glove box.

Remove the cover bypulling down on its frontedge to release thethree clips, then pullingit toward you to releasethe two rear pins.

Remove thepassenger’skick panel(two clips).


4. Remove the glove box frame and plastic cross-piece.

Remove anddiscard this 5 mmwasher bolt.

Remove the glovebox frame (four bolts).

Place protective tape(duct tape) on thepassenger’s side of theglove box opening.

Move aside any vehicle harnessthat may be in the way, and use ahacksaw blade to carefully cutthrough the plastic cross-piece inthe areas shown. Remove anddiscard the plastic cross-piece andthe protective tape.

Place protectivetape on thedriver’s side ofthe glove boxopening.

Release thesetwo lock tabs,then remove therelay assemblyfrom the glovebox frame.


5. Remove the ECM/PCM unit and the bracket.

Remove the mainharness connectorfrom its bracket.

Disconnect theseconnectors fromthe ECM/PCM.

Remove theECM/PCM.


6. Prepare to install the evaporator.

Remove this wire harnessclip from the blower.

Remove andsave thesewasher bolts.

Remove and savethis 6 x 20 mmwasher bolt.

Remove and save this paint-cutting 6 mm nut and 6 x 16 mmwasher-bolt.

BLOWER

VEHICLEHARNESS

Disconnectthe recirculationcontrol motor7P connector.

Remove thesewire harnessclips from theblower.

Disconnectthe blowermotor 2Pconnector.

Disconnect thepower transistor4P connector.

Removethe blowerfrom thedashboard.


Remove and discard theheater baffle plate.

Remove the A/C hole plug fromthe bulkhead by pushing it towardthe engine compartment, thendiscard the plug.

Remove and save theexpansion valve cover(six self-tapping screws).

Get parts group A.

7. Install the evaporator.

Reinstall the expansionvalve cover with thesix self-tapping screwsyou saved.

Carefully install theevaporator into theheater unit. Becareful not to bendthe evaporator pipes.


8. Install the dust and pollen filters.

Install dust and pollenfilters A and B as shown.

Remove anddiscard the twoblower baffles.

Remove thefilter cover.

Reinstall thefilter cover.

9. Reinstall the blower unit and the ECM/PCM.

Set the blowerin place on thelower mountingstud.

Loosely reinstall the two6 x 16 mm washer-boltsyou saved.

Reinstall the 6 mm paint-cutting nut and 6 x 16 mmwasher-bolt you saved,then torque them and thewasher bolts in steps 2and 3 to 10 N.m (7 lb-ft).

Loosely reinstall the6 x 20 mm washer-boltyou saved.


Snap these wireharness clips in placeon the blower unit.

Reconnect thepower transistor4P connector.

Reconnectthe blowermotor 2Pconnector.

Reconnect therecirculation control motor7P connector.

Snap this wireharness clip in place.

BLOWER

VEHICLEHARNESS

Reattach the mainharness connectorto the connectorbracket.

Reconnect themain harnessconnector.

Reconnect theseconnectors to theECM/PCM.

Reinstall theECM/PCM bracket.

Reinstall theECM/PCM.

‘‘‘‘


10. Install the A/C switch knob and the evaporator sensor.

Connect the evaporatorsensor to the sensorharness 2P connectoryou freed in step 5,then snap the connectorclip in the bracket onthe blower unit.

Insert the evaporatorsensor into thesensor hole, thenturn it clockwiseuntil it clicks into place.

Remove anddiscard thesensor holecover.

Remove the blue tapesecuring the evaporatorsensor 2P connector tothe vehicle harness.

HEATER UNITLOWER CASE

VEHICLEHARNESS

Apply protective tape to theheater control panel justbelow the A/C switch holecover.

Insert the A/C switchbutton in the A/C switchhole, then push on thebutton until it clicks intoplace.

FRONT

BLUETAPE

With a smallflat-tip screwdriver,carefully pry outthe A/C switchhole cover anddiscard it.

Remove the ashtray, then remove the self-tappingscrew. Remove the center console by pulling outon the cover to release the clips, then disconnectthe connectors and the illumination bulb.

With Cigarette Lighter/AshtrayWithout Cigarette Lighter/Ashtray

Remove the centerconsole cover bypulling out on thecover to release theclips, then disconnectthe accessory powersocket connector.


11. Raise the vehicle, and remove the front bumper and the splash shield.

Carefully remove thefront bumper (10 clips,two hexhead screws,and two self-tappingscrews), and set itaside.

FRONT Remove and discardthe drain nozzle capfrom the heater unit.

Install the drain cliponto the drain hose.

Install the drainhose clip intothis hole.

HOOKSHOOKS

Remove thesplash shield(five clips).

12. Install the drain hose.

Install the drain hose with the whitepaint mark on the drain nozzle.


13. For vehicles with cruise control, remove the cruise control actuator.

Remove this wireharness clip from themounting bracket.

Remove these washerbolts, then remove thecruise control actuatorand set it aside.

NOTE: Do not loosenor remove the throttlecables from the actuator.

Disconnect the cruisecontrol actuator 4Pconnector.

14. Prepare the engine compartment.

Remove thesebolts, thenremove theresonator.

Remove these bolts, then removethe air cleaner and disconnect itfrom the hose.

Remove thisvacuum hosegrommet fromthe resonator.

Place a shop towelover the throttle body.

Loosen this band.

ENGINEHARNESS

AIR CLEANERRESONATOR

Removethis engineharnessclamp fromits mountingbracket.

Disconnect the intakeair temperature sensor2P connector.


Push the vehicleharness out ofthis clamp.

Release the brake boosterhose clamp from the bulkhead.

Release thesetwo harnessclamps from thebulkhead.

FLAT-TIP SCREWDRIVER

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15. Remove the power steering pump.

Remove the P/S pump (leave its hosesconnected), and carefully set it aside.

Push the P/Shose out of thismounting bracket.

Lift the P/S fluid reservoir off itsbracket (leave its hosesconnected), and set it aside.

Removeand savethe P/S belt.

16. Remove the alternator.Push the alternatorharness out of thisclamp.

Loosen this bolt; don’tremove it until step 7.

Loosen thisbolt; do notremove it.

Remove the twoalternator mountingbolts (loosened insteps 1 and 3),then remove thealternator and set itaside.

Loosen this bolt;don’t remove ituntil step 7.


Get parts group B.

17. Install the heat insulator.

Reinstall the compressorbracket with the mountingbolts removed in step 1.Torque the bolts to 44 N.m(33 lb-ft).Remove this 10 x 35 mm

mounting bolt, and removethe compressor bracket.

Install the heat insulatorwith two 6 x 12 mm flange bolts(yellow-tinted), 95701-06012-08.Torque the bolts to 10 N.m(7 lb-ft).

Reinstall this 10 x 35 mmmounting bolt in this hole.Torque the bolts to 44 N.m (33 lb-ft).

18. Install the condenser and the receiver.

Set the condenser on thecondenser mounts on thefront lower frame.

Install the left and rightcondenser brackets withtwo 6 x 16 mm washer-bolts (gray-colored),93403-06016-05. Torquethe bolts to 10 N.m (7 lb-ft).

FRONT

Mount the receiver to the left sideof the frame with one 6 x 16 mmwasher-bolt (gray-colored)93403-06016-05. Torque the boltto 10 N.m (7lb-ft).


19. Install the condenser and receiver lines.

Apply refrigerantoil to both fittings onthe condenser line,then install the linebetween the receiverand condenser.

Secure the condenser line tothe receiver with one 6 x 25mm flange bolt (yellow-tinted),95701-06025-08. Torque thebolt to 10 N.m (7 lb-ft).

Apply refrigerant oilto its fitting, thenconnect the receiverline to the receiverwith one 6 x 25 mmflange bolt(yellow-tinted),95701-06025-08.Torque the bolt to10 N.m (7 lb-ft).

Install receiverline clip B(80387-SM4-A01)into this squarehole.

Install receiver line clip A(80381-S5A-A01) intothis square hole.

Secure the condenserline to the condenserwith one 6 x 25 mmflange bolt (yellow-tinted),95701-06025-08. Torquethe bolt to 10 N.m (7 lb-ft).

Install the compressor on thecompressor bracket with thefour 8 x 100 mm flange bolts(90023-P2A-000). Torquethe bolts to 24 N.m (17lb-ft).

Secure thecondenser fanassembly with two6 x 16 mm washer-bolts (gray-colored),93403-06016-05.Torque the bolts to10 N.m (7 lb-ft).

20. Install the compressor and the condenser fan.

FRONT

Carefully set thecondenser fanassembly in placeon the condenserfan mounts.


21. Install the A/C wire harness.

Snap this wireharness clipinto the tab onthe condenserfan shroud.

Snap thiswire harnessclip into thehole next tothe groundbolt.

Attach the A/C harnessground terminal here with theground bolt (gold-colored),90153-SE0-003. Torque thebolt to 10 N.m(7 lb-ft).

FRONT

Connect the A/Charness pressureswitch connectorto the receiver.

Connect theA/C harness 3Pconnector to thecompressor, thensnap the connectorto the bracket intothe condenser fanshroud.

With Fog Lights: Without Fog Lights:

FRONT

Remove the blue tape fromthe vehicle harness 4Pconnector, then remove anddiscard the blank connector.

FOG LIGHTHARNESS

Connect this 2Pconnector of the A/C wireharness to the condenserfan connector.

Connect the vehicle harness 4Pconnector to the A/C harness4P connector, then snap theconnector into the bracket.

Secure the A/C wireharness to the foglight wire harnesswith two wire ties(38221-SW5-300).Cut off the excesswire tie.

Attach the A/C wire harness tothe front bulkhead by snappingthe two wire harness clips intothe two holes shown.

Attach thecompressorharness clip tothis tab on thecondenser fanshroud.


Install the A/Ccompressor belt.Make sure the beltis properly alignedin the grooves ofthe pulleys.

22. Install the A/C compressor belt.

Turn the adjusting bolt until thebelt tension reaches the “NewBelt” tension.Do not overtighten!New Belt Tension:830 to 980 N (85 to 100 kg)NOTE: After the A/C kit isinstalled and the engine hasrun for 5 or more minutes (A/Cperformance test), readjust thebelt to the “Used Belt” tension.Used Belt Tension:390 to 540 N (40 to 55 kg)

Torque this bolt toits final torque of44 N.m (33 lb-ft).

Fit the belt tension gauge(T/N 07JGG-001010A) ontothe A/C compressor belt.Do not use any othergauge!

TightenLoosen

Looselyreinstall thealternator.Do nottighten thebolts yet.

Torque this bolt to24 N.m (17 lb-ft).

Torque this bolt to 44 N.m(33 lb-ft), then recheckthe belt tension.

Apply an initial torqueof 19 N.m (14 lb-ft) tothis bolt.


23. Reinstall the power steering pump.

Reinstall the adjustingbolt, and turn it by handto get the proper belttension of 390 to 540 N(40 to 50 kg).Do not overtighten!

Reinstall the P/Shose in the bracket.

Fit the belt tension gauge(T/N 07JGG-01010A) ontothe P/S belt.Do not use any othergauge!

Torque the twomounting nuts to24 N.m (17 lb-ft),then recheck thebelt tension.

Reinstall the P/S pumpand its mounting boltsand nuts. Do not tightenthe bolts and nuts yet.

Reinstall the P/S belt.Make sure the belt isproperly aligned in thegrooves of the pulleys.

Reinstall the P/S fluid reservoirback in its mounting bracket.

24. Install the A/C suction line and receiver line B.

Slide the A/C suction line and receiver line B clamp ontothe mounting stud. Make sure that the throttle and heatercables are not caught or pinched by the bracket, theninstall a 6 mm paint-cutting nut (yellow-tinted),90361-SV4-003. Torque the nut to 10 N.m (7 lb-ft).

Reinstall the brake boosterhose clamp into the squarehole on the bulkhead, thensnap A/C line B into it.

Connect the A/C suctionline and receiver line Bto the evaporator withone 6 x 30 mm flangebolt (yellow-tinted),95701-06030-08, andtwo 6 mm paint-cuttingnuts (yellow-tinted),90361-SV4-003. Torquethe bolt and nuts to10 N.m (7 lb-ft).

Push the brake booster vacuum hose toward theengine, then feed the suction hose on the A/Csuction line and receiver line B under it.

HEATERVALVECABLE

A/C LINE B

THROTTLECABLE


25. Connect the suction line.

Remove and retain this 6 mmflange nut, then remove anddiscard the cap from thesuction side of the compressor.

Install the suction hosebracket to the P/S hosebracket with a 6 x 12 mmwasher-bolt (yellow-tinted),93403-06012-08. Torque thebolt to 10 N.m (7 lb-ft).

Apply refrigerant oil to thesuction hose O-ring, thenloosely connect the suctionhose to the suction line.

Install the suction line bracket with two6 x 16 mm washer-bolts (gray-colored),93403-06016-05. Torque the bolts to10 N.m (7 lb-ft).

Torque this fitting to 33 N.m(24 lb-ft). Make sure youuse a second wrench tohold the other fitting.

Install the suction hoseclamp onto the suction hosebracket, then secure thesuction hose in the clamp.

P/S HOSEBRACKET

Apply refrigerant oil to its O-ring,then connect the suction line to thecompressor with the retained 6 mmflange nut. Torque the nut to 10 N.m(7 lb-ft).

26. Install the discharge hose.

Route the dischargehose below thecompressor clutchwire, and up to thecompressor.

SUCTION PIPESUCTION LINE

Apply refrigerant oil to its O-ring, thenconnect the discharge hose to thecondensor with a 6 x 25 mm flange bolt(yellow-tinted), 95701-06025-08. Torquethe nut to 10 N.m (7 lb-ft).

Apply refrigerant oil to its O-ring, then connect thedischarge hose to the compressor with the retained6 mm flange nut. Torque the nut to 10 N.m (7 lb-ft).

Remove and retain this 6 mmflange nut, then remove anddiscard the cap from thecompressor.

COMPRESSORCLUTCH WIRE


Get parts group C.

27. Install the power relays and the vehicle harness clip.

Install the two powerrelays in the socketsshown.

UNDER-HOODSRS LABEL

(USA) (Others)

28. Attach the labels in the locations shown.

Remove the lid from theunder-hood fuse/relaybox.

Reinstall the fuse/relaybox lid.

Reattach the vehicleharness clips to theirbrackets.

VEHICLE HARNESS

(USA)


29. Reinstall the remaining parts.

Relay assembly and glove box frame

Glove box

Passenger’s dashboard lower cover

Passenger’s kick panel

Center console cover, and reconnect theaccessory power socket or cigarette lighter.

Under-dash fuse/relay box

Driver’s dashboard lower cover

Front bumper and splash shield

Cruise control actuator; tighten the mounting bolts to 10 N⋅m (7 lb-ft).

Power steering pressure switch connector

Brake fluid level switch connector

Resonator and air cleaner case

Reconnect the negative cable to thebattery.

Check for battery voltage at the accessorypower socket (or cigarette lighter).

30. Do the idle learning procedure.

Whenever the battery or the ECM/PCM isdisconnected, the ECM/PCM must relearn theproper idle air control (IAC) values. To do this,follow this procedure exactly.

–1 Start the engine, and turn off all accessories(A/C, radio, defogger, etc.).

–2 Warm the engine up to normal operatingtemperatures (cooling fans come on twice),then let the engine idle for 10 minutes.

If the above procedure is not done correctly, theengine will have an erratic idle.

31. Evacuate the system.

The HFC-134a and compressor oil used in this A/Csystem are highly moisture absorbent. Afterinstalling the system, make sure you evacuate itfor at least 15 minutes.

NOTE:

� If low pressure does not reach more than 700mm Hg (27 in-Hg) in 15 minutes, there isprobably a leak in the system. Partially chargethe system, and check for leaks(see step 32).

� If the system is left open, the desiccant in thereceiver tank will become saturated with moisture,requiring longer evacuation time.

32. Charge the system.

� This system requires only the amount ofHFC-134a refrigerant shown below. If youovercharge the system, the engine and the A/C willmalfunction. Do not overcharge! Select theappropriate units of measure for your refrigerantcharging station.

500 to 550 grams

0.50 to 0.55 kilograms

1.1 to 1.2 pounds

17.6 to 19.4 ounces

� Do not add oil to the compressor; a newcompressor already contains enough oil for theentire A/C system. If you are replacing compressoroil that has leaked out of the system, use onlySanden SP-10 oil.

� Using the wrong oil, or mixing different types of oil,will result in abnormal compressor noise orseizure, or shortened compressor service life.These conditions are not covered by thewarranty policy.

33. Check for leaks.When testing for leaks, follow these guidelines:� Make sure you use a leak detector designed for

A/C systems that use HFC-134a.� To avoid false readings, do not use a tester

designed to detect Freon (CFC-12).� Because HFC-134a is heavier than air, always

check 360° around all fittings.

� If you lose or damage an O-ring during A/Cinstallation, make sure you order the correctreplacement as listed here:

PART NAME PART NUMBER APPLICATION

O-ring, 8 mm 80873-ST7-000 Condenser linereceiver lines

O-ring, 5/8″ 80871-ST7-000 Suction hoseand line

O-ring, 1/2″ 80872-ST7-000 Discharge hoseand line

34. Performance test the A/C system.Refer to Service Bulletin 96-012, Air ConditioningSystem Performance Test, filed under Accessoriesin the old Service Bulletin binder.

35. Readjust the A/C compressor belt tothe “Used Belt” tension: 390 to 540N(40 to 55 kg).Refer to step 22 on page 20.

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