ACURA RL KA9 1996 Service Repair Manual

A/C Compresso r Bel t
Adjustmen t
Deflection Metho d
1 . Appl y a forc e o f 9 8 N (1 0 kgf , 2 2 Ibf) , an d measur e
th e deflectio n betwee n th e A/ C compresso r an d th e
crankshaf t pulley .
A/ C Compresso r Bel t
Use d Belt : 8. 0 - 11. 0 m m (0.3 1 - 0.4 3 in )
Ne w Belt : 5. 5 - 6. 0 m m (0.2 2 - 0.2 4 in )
NOTE :
If ther e ar e crack s o r an y damag e eviden t o n th e
belt , replac e it wit h a ne w one .
"Use d belt " mean s a bel t whic h ha s bee n use d
fo r 5 minute s o r more .
"Ne w belt " mean s a bel t whic h ha s bee n use d
fo r les s tha n 5 minutes .
2 . Loose n th e cente r nu t o f th e idle r pulley .
3 . Tur n th e adjustin g bol t t o ge t prope r bel t tension ,
the n retighte n th e cente r nut .
4 . Rechec k th e deflectio n o f th e A/ C compresso r belt . Tensio
n Gaug e Metho d
1. Attac h th e specia l too l t o th e A/ C compresso r bel t
a s show n below , an d measur e th e tensio n of the
belt .
A/ C Compresso r Bel t
Use d Belt : 44 0 - 64 0 N (4 5 - 6 5 kgf , 99-14 3 Ibf )
Ne w Belt : 93 0 - 1,08 0 N (9 5 - 11 0 kgf , 20 9 - 24 3 Ibf )
NOTE :
If ther e ar e crack s o r an y damag e eviden t o n th e
belt , replac e it wit h a ne w one .
Follo w th e manufacturer' s instruction s fo r th e bel t
tensio n gauge .
"Use d belt " mean s a bel t whic h ha s bee n use d
fo r 5 minute s o r more .
"Ne w belt " mean s a bel t whic h ha s bee n use d
fo r les s tha n 5 minutes .
BELT TENSIO N GAUG E07JGG-00101 0 A
2. Loose n th e cente r nu t o f th e idle r pulley .
3 . Tur n th e adjustin g bol t t o ge t prope r bel t tension ,
the n retighte n th e cente r nut .
4 . Rechec k th e tensio n o f th e A/ C compresso r belt .
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Condenser
Replacemen t
1. Recove r th e refrigeran t wit h a recovery/recycling /
chargin g statio n (se e pag e 22-75 ).
2 . Remov e th e bolt s an d th e uppe r moun t bracket s
fro m th e radiator .
6 x 1. 0 m m9.8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
3.Remov e th e bolts , the n disconnec t th e condense r
lin e an d th e receive r lin e B fro m th e condenser .
Remov e th e receiver/drye r mountin g bolt s fro m th e
condenser .
NOTE: Plu g o r ca p th e line s immediatel y afte r dis -
connectin g the m to avoi d moistur e an d dus t con -
tamination .
RECEIVER LIN E BCONDENSE R LIN E
6 x 1. 0 m m9.8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )RECEIVER/DRYE R
4. Remov e th e bolts , the n disconnec t th e discharg e
lin e an d th e receive r lin e A fro m th e condenser .
NOTE : Plu g o r cap the line s immediatel y afte r dis -
connectin g the m to avoi d moistur e an d dus t con -
tamination .
RECEIVER LIN E A6 x 1. 0 m m9.8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
DISCHARG E LIN E
5. Remov e th e mountin g nut s fro m th e condenser .
6 x 1. 0 m m8 N- m (0. 8 kgf-m , 6 Ibf-ft )
UPPE R MOUN TBRACKET S
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6. Remov e th e bolt s an d th e uppe r moun t bracket s
from th e condense r a s shown .
UPPER MOUN T BRACKET S
7. Remov e th e condense r b y liftin g i t u p a s shown .
NOTE : B e carefu l no t t o damag e th e radiato r an d
th e condense r fin s whe n removin g th e condenser.
CONDENSE R
8. Instal l i n th e revers e orde r o f removal . Mak e not e o f
th e followin g items .
If you'r e installin g a ne w condenser , ad d refriger -
an t oi l (ND-OI L 8 ) (se e pag e 22-73 ).
Replac e th e O-ring s wit h ne w one s a t eac h fit -
ting , an d appl y a thi n coa t o f refrigeran t oi l
befor e installin g them .
NOTE : B e sur e t o us e th e righ t O-ring s fo r HF C -
134 a ( R - 134a ) t o avoi d leakage .
B e carefu l no t t o damag e th e radiato r an d th e
condense r fin s whe n installin g th e condenser .
B e sur e t o instal l th e lowe r moun t cushion s o f
condense r securel y int o th e holes .
Charg e th e syste m (se e pag e 22-89 ), an d tes t it s
performanc e (se e pag e 22-76 ).
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A/C Syste m Servic e
Evacuatio n
Use onl y servic e equipmen t tha t i s U.L.-liste d an d i s cer -
tifie d t o mee t th e requirement s o f SA E J221 0 t o remov e
HFC-134 a (R-134a ) fro m th e ai r conditione r system .
CAUTION : Exposur e t o ai r conditione r refrigeran t an d
lubrican t vapo r o r mis t ca n irritat e eyes , nos e an d throat .
Avoi d breathin g th e ai r conditione r refrigeran t an d lubri -
can t vapo r o r mist .
I f accidenta l syste m discharg e occurs , ventilat e wor k
are a befor e resumin g service .
R-134 a servic e equipmen t o r vehicl e ai r conditione r sys -
tem s shoul d no t b e pressur e teste d o r lea k teste d wit h
compresse d air .
Som e mixture s o f ai r an d R-134 a hav e bee n
show n to b e combustibl e a t elevate d pressure s an d ca n
resul t i n fir e o r explosio n causin g injur y o r propert y
damage . Neve r us e compresse d ai r t o pressur e tes t R -
134 a servic e equipmen t o r vehicl e ai r conditione r sys -
tems .
Additiona l healt h an d safet y informatio n ma y b e obtaine d
fro m th e refrigeran t an d lubrican t manufacturers .
1 . Whe n a n A/ C syste m ha s bee n opene d t o th e atmo -
sphere , suc h a s durin g installatio n o r repair , i t mus t
b e evacuate d usin g a R-134 a refrigeran t recovery /
recycling/chargin g station . (I f th e syste m ha s bee n
ope n fo r severa l days , th e receiver/drye r shoul d b e
replaced , an d th e syste m shoul d b e evacuate d fo r
severa l hours. )
RECOVERY/RECYCLING/CHARGIN G STATIO N
LOW-PRESSUR ESIDE
HIGH-PRESSUR E
SID E
2. Connec t a R-134 a refrigeran t recovery/recycling /
chargin g statio n t o th e vehicle , a s shown , followin g
th e equipmen t manufacturer' s instructions .
NOTE : I f th e lo w pressur e doe s no t reac h mor e tha n
93. 3 kP a (70 0 mmHg , 27. 6 in.Hg ) i n 1 5 minutes , ther e
i s probabl y a lea k i n th e system . Partiall y charg e th e
system , an d chec k fo r leak s (se e Lea k Test) .
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Charging
Use onl y servic e equipmen t tha t i s U.L.-liste d an d is cer -
tifie d t o mee t th e requirement s o f SA E J221 0 t o remov e
HFC-134 a (R-134a ) fro m th e ai r conditione r system .
CAUTION : Exposur e t o ai r conditione r refrigeran t an d
lubrican t vapo r o r mis t ca n irritat e eyes , nos e an d
throat . Avoi d breathin g th e ai r conditione r refrigeran t
an d lubrican t vapo r o r mist .
I f accidenta l syste m discharg e occurs , ventilat e wor k
are a befor e resumin g service . Additiona l healt h an d
safet y informatio n ma y b e obtaine d fro m th e refrigeran t
an d lubrican t manufacturers .
Selec t th e appropriat e unit s o f measur e fo r you r refrig -
eran t chargin g station .
Refrigeran t capacity :
700 to 75 0 g
0.7 0 to 0.7 5 kg
1.5 t o 1. 6 lbs .
24.7 to 26. 5 oz.
CAUTION : D o no t overcharg e th e system ; th e compresso r
wil l b e damaged .
Connec t a R-134 a refrigeran t recovery/recycling/chargin g
station to th e vehicle , a s shown , followin g th e equipmen t
manufacturer' s instructions .
RECOVERY/RECYCLING/CHARGIN G STATIO N
LOW-PRESSUR ESIDE
HIGH-PRESSUR ESIDE
Lea k Tes t
Use onl y servic e equipmen t tha t i s U.L.-liste d an d i s cer -
tifie d t o mee t th e requirement s o f SA E J221 0 t o remov e
HFC-134 a (R-134a ) fro m th e ai r conditione r system .
CAUTION : Exposur e t o ai r conditione r refrigeran t an d
lubrican t vapo r o r mis t ca n irritat e eyes , nos e an d throat .
Avoi d breathin g th e ai r conditione r refrigeran t an d lubri -
can t vapo r o r mist .
I f accidenta l syste m discharg e occurs , ventilat e wor k
are a befor e resumin g service .
R-134 a servic e equipmen t o r vehicl e ai r conditione r sys -
tem s shoul d no t b e pressur e teste d o r lea k teste d wit h
compresse d air .
Som e mixture s o f ai r an d R-134 a hav e
bee n show n t o b e combustibl e a t elevate d pressure s
an d ca n resul t i n fir e o r explosio n causin g injur y o r
propert y damage . Neve r us e compresse d ai r t o pressur e
tes t R-134 a servic e equipmen t o r vehicl e ai r conditione r
systems.
Additiona l healt h an d safet y informatio n ma y b e obtaine d
fro m th e refrigeran t an d lubrican t manufacturers .
1 . Connec t a R-134 a refrigeran t recovery/recycling /
charging statio n to th e vehicle , a s show n in th e pre -
viou s colum n followin g th e equipmen t manufactur -
er' s instructions .
NOTE : B e sur e t o instal l th e sam e amoun t o f ne w
refrigeran t oi l bac k int o th e A/ C syste m befor e charg -
ing.
2. Ope n th e high-pressur e valv e t o charg e th e syste m
t o th e specifie d capacity , the n clos e th e suppl y
valve , an d remov e th e chargin g syste m couplers .
Selec t th e appropriat e unit s of measur e fo r you r
refrigeran t chargin g station .
Refrigeran t capacity :
700 to 75 0 g
0.7 0 to 0.7 5 k g
1.5 t o 1. 6 lbs .
24.7 to 26. 5 oz.
3. Chec k th e syste m fo r leak s usin g a R-134 a refriger -
an t lea k detecto r wit h a n accurac y o f 1 4 g (0. 5 oz )
pe r yea r o r better .
4 . I f yo u fin d leak s tha t requir e th e syste m to b e opene d
(t o repai r o r replac e hoses , fittings , etc.) , recove r th e
syste m accordin g to th e Recover y Procedur e o n pag e
22-75 .
5. Afte r checkin g an d repairin g leaks , th e syste m mus t
b e evacuate d (se e Syste m Evacuatio n o n pag e 22-88 ).
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Special Tool s
07LAJ-PT3020 A
07PAZ-001010 0
23-86
23-24 8
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Troubleshooting
Tips an d Precaution s
Before Troubleshootin g
• Chec k applicabl e fuse s i n th e appropriat e fuse/rela y
box.
• Chec k th e batter y fo r damage , stat e o f charge , an d
clea n an d tigh t connections .
• Chec k th e alternato r bel t tension .
CAUTION :
• D o no t quick-charg e a batter y unles s th e batter y
groun d cabl e ha s bee n disconnected , otherwis e yo u
wil l damag e th e alternato r diodes .
• D o no t attemp t t o cran k th e engin e wit h th e batter y
groun d cabl e loosel y connecte d o r yo u wil l severel y
damag e th e wiring .
Handlin g Connector s
• Mak e sur e th e connector s ar e clea n an d hav e n o loos e
wire terminals .
• Mak e sur e multipl e cavit y connector s ar e packe d wit h
greas e (excep t watertigh t connectors) .
• Al l connector s hav e push-dow n releas e typ e locks .
LOCKIN G TA B
LOCKIN G TA B
• Som e connector s hav e a cli p o n thei r sid e use d t o
attac h the m t o a moun t bracke t o n th e bod y o r o n
anothe r component . Thi s cli p ha s a pul l typ e lock .
• Som e mounte d connector s canno t b e disconnecte d
unles s yo u firs t releas e th e loc k an d remov e th e
connecto r fro m it s moun t bracket .
LOCKINGPAWL O N
OTHE R
HAL F O F
CONNECTO R
Pull t odisengag eBRACKET
• Th e back s o f som e connector s ar e packe d wit h
grease . Ad d greas e i f necessary . I f th e greas e i s
contaminated , replac e it .
•
Chec k fo r loos e retaine r an d rubbe r seals .
RETAINE RRUBBER SEA LRETAINE R
• Neve r tr y t o disconnec t connector s b y pullin g o n
thei r wires ; pul l o n th e connecto r halve s instead .
• Alway s reinstal l plasti c covers .
• Befor e connectin g connectors , mak e sur e th e
terminal s ar e i n plac e an d no t bent .
BENT TERMINA L
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Troubleshooting
Tips an d Precaution s (cont'd )
• Inser t th e connecto r al l th e wa y an d mak e sur e i t i s
securel y locked .
• Positio n wire s s o tha t th e ope n en d o f th e cove r face s
down .
Faceope n en ddow n
Handlin g Wire s an d Harnesse s
• Secur e wire s an d wir e harnesse s t o th e fram e wit h
thei r respectiv e wir e tie s a t th e designate d locations .
• Remov e clip s carefully ; don' t damag e thei r locks .
EXPANSIO NCLIP LOCK S
Slip plier s unde r th e cli p bas e an d throug h th e hol e a t
a n angle , the n squeez e th e expansio n tab s t o releas e th e
clip .
SNAP-RIN G PLIER S
• Afte r installin g harnes s clips , mak e sur e th e harnes s
doesn' t interfer e wit h an y movin g parts .
• Kee p wir e harnesse s awa y fro m exhaus t pipe s an d
othe r ho t parts , fro m shar p edge s o f bracket s an d
holes , an d fro m expose d screw s an d bolts . •
Refe r t o th e instruction s i n th e Hond a Termina l Ki t fo r
identificatio n an d replacemen t o f connecto r
terminals .
•
Us e a prob e wit h a tapere d tip .
•
Sea t grommet s i n thei r groove s properly .
NOT GOO D
Testin g an d Repair s
• D o no t us e wire s o r harnesse s wit h broke n insulation .
Replac e the m o r repai r the m b y wrappin g th e brea k
wit h electrica l tape .
• Afte r installin g parts , mak e sur e tha t n o wire s ar e
pinche d unde r them .
• Whe n usin g electrica l tes t equipment , follo w th e
manufacturer' s instruction s an d thos e describe d i n
thi s manual .
• I f possible , inser t th e prob e of the teste r fro m th e
wir e sid e (excep t waterproo f connector) .
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Five-step Troubleshootin g
1. Verif y Th e Complain t
Tur n o n al l th e component s i n th e proble m circui t t o
verif y th e custome r complaint . Not e th e symptoms .
D o no t begi n disassembl y o r testin g unti l yo u hav e
narrowe d dow n th e proble m area .
2. Analyz e Th e Schemati c
Look u p th e schemati c fo r th e proble m circuit .
Determin e ho w th e circui t i s suppose d t o wor k b y
tracin g th e curren t path s fro m th e powe r fee d
throug h th e circui t component s t o ground . I f severa l
circuit s fai l a t th e sam e time , th e fus e o r groun d is a
likel y cause .
Based o n th e symptom s an d you r understandin g o f
th e circui t operation , identif y on e o r mor e possibl e
cause s o f th e problem .
3 . Isolat e Th e Proble m B y Testin g Th e Circui t
Mak e circui t test s t o chec k th e diagnosi s yo u mad e
in ste p 2 . Kee p i n min d tha t a logical , simpl e
procedur e i s th e ke y t o efficien t troubleshooting .
Tes t fo r th e mos t likel y caus e o f failur e first . Tr y t o
mak e test s a t point s tha t ar e easil y accessible .
4 . Fi x Th e Proble m
Onc e th e specifi c proble m is identified , mak e th e
repair . B e sur e t o us e prope r tool s an d saf e
procedures .
5 . Mak e Sur e Th e Circui t Work s
Turn o n al l component s i n th e repaire d circui t i n al l
mode s t o mak e sur e you'v e fixe d th e entir e
problem . I f th e proble m wa s a blow n fuse , b e sur e
t o tes t al l o f th e circuit s o n th e fuse . Mak e sur e n o
ne w problem s tur n u p an d th e origina l proble m
doe s no t recur .
Wire Colo r Code s
The followin g abbreviation s ar e use d t o identif y wir e
color s in th e circui t schematics :
WHT .............................Whit e
YEL............................... Yello w
BL K ............................. . Blac k
BL U ............................. . Blu e
GR N ............................ . Gree n
RED ............................. . Red
OR N ............................ . Orang e
PNK ............................. . Pink
BRN ............................. . Brown
GRY............................. . Gra y
PU R ............................. . Purpl e
L T BL U ........................ . Ligh t Blu e
L T GR N ....................... . Ligh t Gree n
Th e wir e insulatio n ha s on e colo r o r on e colo r wit h
anothe r colo r stripe . Th e secon d colo r i s th e stripe .
WHT/BL K
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Relay an d Contro l Uni t Location s
Engine Compartmen t
TCS FAIL-SAF E RELA Y('96-99 models )
• FRON T SEA T HEATE R
RELA Y ('9 8 model )
• ACCESSOR Y POWE R
SOCKE T RELA Y
('9 9-0 1 models )
UNDER-HOO D RELA Y
BOX C
RADIATO R FA NRELA Y
VSA MODULATO R UNI T('00 - 01 models )
• POWE R WINDO W
MASTE R SWITC H
RELAY('96-9 7 models )• TAILLIGH T RELA Y
('9 9-0 1 models )WINDSHIEL
D WIPE R
MOTO R RELA Y
- AB S REA R FAIL-SAF E
RELAY('96-9 7 models )• HOR N RELA Y
('9 8-0 1 models )
FRON T FO G LIGH T
RELA Y
• AB S FRON T FAIL-SAF E
RELA Y ('96-9 7 models )
• AB S FAIL-SAF E RELA Y
('98-99 models )
GAUGE RELA Y
A/ T REVERS ERELAY
REAR WINDO W
DEFOGGE R RELA Y
WINDSHIEL D WIPE R
INTERMITTEN TRELAYRADIATO R FA N
MAI N RELA Y CONDENSE
R FA NRELA YA/C COMPRESSO R
CLUTC H RELA Y
•
LO W BEA M CU T RELA Y
(Canada : '9 6 - 9 8 models )
• SECURIT Y HOR N RELA Y
(USA: '99-0 1 models )
• LO W BEA M CU T RELA Y
(Canada : '0 0-0 1 models )
UNDER-HOO D RELA Y
BOX A
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