out HONDA CIVIC 1996 6.G Workshop Manual

RecirculationindicatorIightindicatesDiagnosticTroublecode(DTc)2:AprobIemintheairmixcontro|motorcircuit.
The air mix control motor regutates the mi)dure of cool/hot air according to outputs from the heater control panel'
Self-diagnosis circuit check indi-
crl6s a problgm in tho air mix
contiol motor circuit.
Check th6 rir mix control motor:
1. Disconnect the air mix control
motor 5P connector'
2. Test the air mix control motor(see page 21-46).
Check the air mix control linkage
and doors:1. Remove the air mix control
motor (see page 21'46).
2. Check the air mix control link-
age and doors for smooth
ls the air mix control motor OK?
Do the air mix control linkage and
doors move smoothlY?
Roglace the air mix conlrol motor.
Check for r short in the wiresl
1. Disconnect the heater controlpanel 20P connector.2. Check for continuity between
body ground and the heater
control panel 20P connector
terminafs No. 3,4. 12,15 a^d
20 individually
Bep.ir any short in the wire{s)
between the h€rter control panel
and th6 air mix control motor.ls there continuity?
HEATER CONTROL PANEL 2OP CONNECTOR
BEO/WHTREO/YEL
PNK/BLK
Wire side of female terminals
(cont'd)
Io page 21-24
21-23

Troubleshooting -'99 - 00 Models
Heater Control Panel Input/Output Signals
HEATER CONTROL PANEL CONNECTORS
8P CONNECTOR2OP CONNECTOR12P CONNECTOR
Wire side of female terminals
8P CONNECTOR (O qn Circuit Diagram)
20P CONNECTOR {D on circuit Diagram}
*: with Ay'c
12P CONNECTOR (tr on Circuit Diagraml
CavityWire colorSignalCavilyWhe colorSignal
BLU/8LKBLOWER FEEDBACKINPUT5REDDASH LIGHTS BRIGHTNESSCONTROLLEROUTPUT
2GRN/lVHTFRESHINPUT6BLKGBOU N DOUTPUT
3GRN/REDRECIRCULATEINPUT7BLU/YELREAR WINDOW DEFOGGERRELAYOUTPUT
4RED/BLKCOMBINATION LIGHT SWITCH(Via No. 30 (7.5 A) fuse)INPUT88LfiELlG2 {Power)INPUT
CavityWire colorSignalCavityWire colorSignal
LTGRN/BLKPOWER TRANSISTOR EASEOUTPUT't1BLU/REDAy'C THERMOSTATINPUT
2BRNMHTMODE CONTROL MOTORGROUNDINPUT12BRNAIR MIX CONTROL MOTORGROU NDINPUT
3RE D/YELAIR MIX HOTOUTPUT13ORNAA/HTBLOWER MOTOR HIGHRELAYINPUT
RED,ryvHIAIR MIX COOLOUTPUT14
5YEUBLUMODE DEFINPUTPN K,/BLKAIR MIX POTENTIALOUTPUT
6YEUREDMODE VENTINPUT16
7GRNI/ELMODE HEAT/r'ENTINPUT11
IBLUAVHTMODE HEATINPUT18
9YELMODE HEAT/DEFINPUT19
10WHT/BLU+B (Power)INPUT20GRYAIR MIX POTENTIAL +5 VOUTPUT
CavityWilecolorSignalCavityWi.e cololSignal
lSWITCH LED COMMONOUTPUT1SWITCH LIGHTS +OUTPUT
2ISWITCH LIGHTS -INPUT
39SWITCH COMMONINPUT
4RECIRCULATION CONTROLSWITCH LEDINPUT10A,/C SWITCHOUTPUT
5A./C SWITCH LEDINPUT11RECIRCULATION CONTROLSWITCHOUTPUT
6REAR WINDOW DEFOGGERSWITCH LEDINPUT12REAR WINDOW DEFOGGEBSWITCHOUTPUT
21-36

Blower Unit
Replacement
NOTE: The blower motor, recirculation control motor
and blower resistor can bs replacsd without rsmoving
th€ blower unit (see neld Page).
1. Move the temperature control to "HOT."
'96-98: Slide the temperature control lever.'99-00: Turn the ignition switch ON (ll), then turn
the temperature contol knob. Turn the ignition
switch off,
Remove the glovs box (ses ssction 20),
R€move ths s6lf-tapping screw and ths passsng6r's
dashboard low€r cover. Removo the bolt, the nut
and the kn€e bolst€r, then remove the fiv€ bolts and
the glove box trame,
Without Air Condhioning
4-a. Remove the wiro harness from the h68t€r duct, then
remove the two self-tapping scrsws and the heatsr
duct.
KNEE
GLOVE BOX FRAME
HEATER DUCT
21-37
Wrth Air Conditioning
4-b. Removo th6 ev8porator (sss pago 22-28).
6x1.0m|n9.8 N'm
6x1.0mm9.8 N'm lt'o tgf'm, t.2 lb{'ttl
Disconnoct the connectors trom th€ blower motor,
blowor r6sistor {'96 - 98 models), power transiator
('99 - 0O modsls), blowor motor high telay ('99 - 00
models) and recirculation control motor.
R€mov€ ths wiro harnoss clip from tho recirculation
control motor, and release the wir6 harnsss from ths
clamo on the blowor unit. Remove the two mount-
ing bolts, tho mounting nut and ths blowor unit'
9.8 .m 11.0 tgfm,1.2 tblfrl
lnstall in ths reverso order of removal. Mako surs
that thsre is no air leaka96.
6x1.0mm9,t N'm 11.0lgi.m,7.2 tbf.fil

Blower Unit
Overhaul
NOTE:
RECIRCULATIONCONTROL MOTORTest, page 21-48
aBefore reassembly. make sure that the recirculation control door and linkage move smoothly without binding.
When attaching the recirculation control motor, make sure its positioning will not allow the recirculation control door
to be pulled too far.
After aftaching the recirculation control motor, connect power and ground, and watch the movement of the recircula-
tion control door.
BLOWERTest, page 2'l 9{'96 - 98 modebl
POWER TRANSISTOR l'99 - 00 modeblTest, page 21-50
Test, page 21'10 ('96 98 models) orpage 21'31 ('99 00 models)
m
MOTOR
2134

Heater Unit
Replacement
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section {24} before performing repairs or ser-
L Disconnect the negative cable from the battery.
2. Frcm under the hood, open the clamp, then discon-
nect the heater valve cable from the heater valve
arm. Turn the heater valve arm to the fully opened
position as shown.
When the engine is cool. drain the engine coolant
from the radiator (see section 10).
!@ Do not remove the radiator cap when
the engine is hot; the ongine coolant is under pres'
surg and could severely scald you.
CLAMP
HEATER VALVC CABLE
4. Disconnect the heater hoses from the heater unit.
CAUTION: Engine coolant will damage p8int.
Ouickly rinse any spilled engins coolant from painted
su aces,
NOTE: Engine coolant will run out when the hoses
are disconnected; drain it into a clean drip pan.
5. Remove the mounting nut from the heater unit.
NOTE: When removing the mounting nut, take care
not to damage or bend the fuel lines, the brake
lines, etc.
I x 1 .25 mm22 N.m {2.2 kgl.m, 16lblftl
21-39

Heater Unit
Replacement (cont'dl
6.
7.
8.
9.
Remove the dashboard (see section 20).
Remove the heater duct (see page 21-37) or evapo-
rator (see page 22-28).
Disconnect the connectors from the mode control
motor and air mix control motor ('99 - 00 models),
then remove the wire harness clips and wire har-
ness from the heater unit. Remove the clip from the
heater duct, then remove the two mounting nuts
and the heater unit.
6x1.0mm9.8 N.m 11.0 kgl.m,7.2 lbf.ftl
HEATER UNIT
lnstall in the reverse order of removal. Make note of
the following items.
Apply sealant to the grommets.
Do not interchange the inlet and outlet heater
hoses. Make sure that the clamps are secure.
Refill the cooling system with engine coolant
(see section 10).
Connect all cables, and make sure they are prop-
erly adjusted (see page 21-44 (96 - 98 models)
or page 21-45 ('99 - 00 models)).
Make sure that there is no air leakage.
21-40

Overhaul
'1. Remove the two self-tapping screws and the heater
core cover.
2. Pull out the grommet from the heater core pipes.
3. Remove the self-tapping screw and the clamp.
GROMMET
Pull out the heater core from the heater unit.
NOTE: Be careful not to bend the inlet and outlet
pipes during heater core removal.
Assemble in the reverse order of disassembly.
HEATER CORE COVER
21-41

Overhaul -'96 - 98 Models
HEATER FAN SWITCHTest, page 21-49
Air Mix Control Cable Replacomenl
1. Cut the inner cable on the lever side of the cable holder, then remove both pieces of the inner cable.
2. Using a sharp knife, cut completely through the end of the cable housing at the two locations.
3. Slidethe largesection ofthecable housing outofthe cable holder, being careful not to da mage the cable stops.
4. Carefully remove the cut pieces of the cable housing with a small flat tip screwdriver.
5. Hook the tip of the new air mix control cable to the temperature control lever, then push the cable housing into the
cable holder until it locks into place.
NOTE: After assembly, check that the temperature control lever slides smoothly through the full stroke lrom right to left.
21-43

Temperature Control
Adjustment -'96 - 98 Models
1. From under the hood, disconnect the heater valve
cable from the heater valve.
TERVALVECABLEHEATER VALVE ARM
2.From under the dash, disconnect the air mix control
cable housing from the cable clamp,
AIR MIXCONTROLARM
3.Set the temperature control lever to MAX. COOL.
With the air mix control cable attached to the air
mix control arm, gently pull on the outer cable
housing to fully close the door and to remove any
slack in the cable. Don't pullto hard, or the temper-
ature control lever will move.
Hold the air mix control arm against the stop. then
snap the air mix control cable housing into the
cable clamp.
21-44
6. From under the hood. move the heater valve arm to
the fully closed position. then attach the heater
valve cable to the heater valve arm.
7. Hold the heater valve arm in the closed position,
and gently pull on the heater cable outer housing to
take up any slack. then install the heater valve cable
housing into the cable clamp.
HEATER VALVE ARM

Air Conditioning
Speciaf Tools ......'.....' 22-2
f f f ustrated f ndex ......................... ".......' 22-3
Wiring/Connector Locations'.........'.... 22'4
Description
Outfine ............ .......22-s
Circuit Diagram
'96 - 98 Models ......"..........".......'.... 22-6
'99 Modef """""""' 22-7
Troubleshooting
Symptom Chart ".'......""................. 22-8
Flowcharts
Condenser Fan .........".................,..'. 22-9
Compressor .....""" 22-12
A/C System .........'.22'17
A/C Thermostat
Test ........'.......' """'22'21
Relays
Test ....."'......... ..""'22-21
A/C Service Tips and Precautions ......22-22
A/C System Torque Specifications '...22-23
A/C System Service
Performance Test ... '."......... ".... ....'..22-24
Pressure Test Chart .................. .... "' 22-26
Recovery ...".........," 22-27
Evaporator
Replacement .....",' 22'24
Overhauf .....-.....""' 22'29
Compressor {SANDEN}
Repf acement ......'.' 22-30
fffustrated fndex ......"..................'.... 22'32
Cf utch Inspection ......... "............ ...... 22-33
Clutch Overhau I ........................ ....... 22-34
Thermal Protector Replacement .... 22-36
Relief Valve Replacement ......'..."". 22-36
Compressor (DENSO)
Repfacement ..""',' 22-37
lf lustrated Index ............................... 22-39
Clutch lnspection ............."'...... "'.... 22-40
Cf utch Overhaul .....................'......... 22-41
Ref ief Valve Replacement'..'......"'.. 22-42
A/C Compressor Belt
Adiustment ............22'43
Condenser
Repfacement .......,,22'44
A/C System Service
Evacuation ...,,,.......22-45
Charging '..........--'..22'46
Leak rest """""""'22-46