Stall test HONDA CIVIC 1996 6.G Repair Manual

Compressor (DENSOI
Replacement (cont'd)
9. Remove the bolts, the suction service valve and theO-ring from the compressor,
lf necessary, remove the compressor bracket as fol-lows.
. Remove the nut and the washer from the left frontmount. When tightening the nut to the left frontmount, make sure the washer is set p.operly onthe left front mount as shown.
a Remove the mounting bolts and the compressor
bracket.
12 x 1,25 rnm59 N.m 16.0 kgfrm,
10.
LEFT FRONTMOUNT€ rbf.fi)Roplace.
WASHEB
x 1.25 mm
2s.5 N.m {2.6 kgf.m. 18.8 tbtttl
4/r N.m {4.5 kgf.m, 33 lbt ft}
22-3A
1 1. Install in the reverse order of removal, and note thesertems:
lf you're installing a new compressor. drain all therefrigerant oil from the removed compressor. andmeasure its volume. Subtract the volume ofdrained oil from '140 ml (4 28 fl{,z, 4.9 lmpoz); theresult is the amount of oil you should drain fromthe new compressor (through the suction fifting).Replace the O-rings with new ones at each fining,and apply a thin coat of refrigerant oil beforeinstalling them. Be sure to use the right O,ringsfor HFC-134a (R-134a) to avoid leakage.
Use refrigerant oil {DENSO, ND-OtL8) for HFC-134aDENSO piston type compressors only.To avoid contamination, do not return the oil tothe container once dispensed, and never mix itwith other refrigerant oils.
lmmediately after using the oil, replace the capon the container, and seal it to avoid moisture
absorption.
Do not spill the refrigerant oil on the vehicle; itmay damage the paint; if the refrigerant oil con-tacts the paint, wash it off immediatelv.
Adjust the ly'C compressor belt (see page 22-43)and the power steering pump belt (see section 17).Charge the system (see page 22-46), and test itsperformance (see page 22-24!..

Compressor (DENSO)
Clutch Overhaul (cont'd)
Remove the screw from the field coil ground termi-nal. Remove the snap ring A with snap ring pliers.
then remove the field coil. Be careful not to damaoethe field coil and compressor.
SNAP NING AReplace.
Reassemble the compressor clutch in the reverseorder of disassembly, and note these rrems:
o Install the field coil with the wire side facingdown.
a Clean the pulley and compressor sliding surfaceswith non-petroleum solvent.. Install new snap rings, and make sure thev arefully seated in the groove.
. Make sure that the pulley turns smoothly afterit's reassembled.
. Route and clamp the wires p.operly or they canbe damaged by pulley.
FIELOcorL
22-42
13.2 N.m 11.35 kgt m,9.76lbtttl
Relief Valve Replacement
L
4.
Recover the refrigerant with a recovery/recycling/charging station {see page 22-27),
Remove the relief valve and the O-ring. plug theopening to keep foreign matter from entering thesystem and the compressor oilfrom running out.
Clean the mating surfaces.
Replace the O-ring with a new one at the relief valve.and apply a thin coat of refrigerant oil before install-ing it.
Remove the plug, and install and tighten the reliefvatve.
Charge the system (see page 22-46), and test its per-formance (see page 22-24),

Condenser
Replacement
1.Recover the refrigerant with a recovery/recycling/
charging station lsee page 22-271.
Disconnect the condenser fan connector from theAy'C wire harness, then remove the A,/C wire harnessfrom the condenser fan shroud.
Remove the bolts, then disconnect the dischargeand condenser lines from the condenser.
NOTE: Plug or cap the lines immediately after dis-connecting them to avoid moisture and dust con-tamination,
6r1.0
6x1.0mmolscHARGE L|NE 9.8 N.m 11.0
9.8 N.m 11.0 kgl.m, 7.2 lbf.ftl
22-44
4. Remove the bolt from the suction hose bracket, andremove the two bolts and the upper mount bracket.Remove the condenser assembly by lifting it up.
NOTE: Be careful not to damage the condenser finswhen removing the condenser assembly.
UPPER MOUNT BRACKET
5. Install in the reverse order of removal. Make note ofthe following items.
. lf you're installing a new condenser, add refriger-ant oil (SANDEN, SP-10 or DENSO, ND-O|L 8)
\see page 22-22l.-
. Replace the O-rings with new ones at each fit-ting, and apply a thin coat of refrigerant oilbefo.e installing them.
NOTE; Be sure to use the right O-rings for HFC,134a (R-134a) to avoid leakage.o Be careful not to damage the condenser finswhen installing the condenser assembly.. Charge the system (see page 22-46), and test itsperformance (see page 22-24i.
6x1.0mm9,8 N.m 11.0 kg{.m, 7.2lbtft}
6x1.0mm9.8 N.m 11.0 kst m, 7.2 lbf.ftl

A/C System Service
Evacuation
Use only service equipment that is U L.-listed and is cer-
tified to meet the requirements oJ SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system'
CAUTION: Exposure to air conditioner reftig€lant and
lubricant vapor or misi can irrhaie eyes. noso and throat'
Avoid breathing the ail condhioner lefrigelant and lubri
cant vapor or mist.
lf accidental system discharge occurs, ventilate work
area before resuming servace.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
comDressed air.
!!@@ some mixtures of air and R-13'[8 haYo boon
ffiiE-n to be "ombustible at elovatod pressurcs and can
result in fire or explosion causing iniury or propsrtY
damag€. Never uso complsssod air to pre3surs tost R-
1344 ssrvico equipment or vehicle air conditioner sy3-
tems,
Additional health and safety information may be obtained
from the refrigerant and lubricant manuJacturers'
When an A,/C System has been opened to the atmo-
sphere, such as during installation or repair, it must
be evacuated using a R-134a refrigerant recovery/
recycling/charging station. (lf the system has been
open for several days, the receiver/dryer should be
replaced, and the system should be evacuated for
several hours.)
Connect a R-134a refrigerant recovery/
recycling/charging station to the vehicle, as shown'
following the equipment manufacturer's instruc-
trons.
NOTE: lf low pressure does not reach more than 93 3
kPa (7OO mmHg,27.6 in.Hgl in 15 minutes, there is
probably a leak in the system Partially charge the
system, and check for leaks (see Leak Test)
1.
R6covory/Recyclin g/Chal9ing Station
22-45'

A/C System Service
Charging
Use only service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irritale eyes, nose and
throat. Avoid breathing the air conditioner retrigerant
and lubricant vaoor or mist,
lf accidental system discharge occurs, ventilate workarea before resuming service, Additional health and
safety information may be obtained from the refrigerant
and lubricant manufacturers.
Refrigerant capacityt 600 - 650 g 121.1 - 22.9 ozl
CAUnON: Do not overcharg€ the system; the comprcssor
will be damaged.
Connect a R-134a refrigerant recovery/recycling/charging
station to the vehicle, as shown, following the equipment
manufacturer's instructions.
Recovery/Recycling/Charging Station
22-46
Leak Test
Use only service equipment that is U.L,-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposure io air conditioner refrigerant and
lubricant vapot or mist can itritats eyes, no36 and thtoat.
Avoid breathing the air conditioner refrigeranl and lubri-
cant vapor or mist,
lf accidental system discharge occurs, ventilate workarea betore resuming service.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
comoressed air.
@ some mixtures of air and R-134a have
been shown to be combugtibls at elevatgd prossures
and can result in tire or explosion causing iniuly orplopgrty damage. Nev€r usc compre33od air to pressure
test R-13'la servica oquipment or yohiclo air conditionor
systems.
Additional health and safety information may be obtained
from the refrigerant and lubricant manufacturers.
1. Connect a R-134a refrigerant recove rylrecycling/
charging station to the vehicle, as shown in the pre-
vious column, following the equipment manufactur-
er's instructions.
NOTE; Be sure to install the same amount of new
refrigerant oil back into the A,/C system before charg-In9.
Open the high-pressure valve to charge the system
to the specified capacity, then close the supply
valve, and remove the charging system couplers.
Rofrigerant capacity: 600 - 650 g (21.1 - 22.9 oz)
Check the system for leaks using a R-134a refriger-
ant leak detector with an accuracy of 14 9 10.5 ozlper yea. or better.
lf you find leaks that require the system to be opened(to repair or replace hoses. fittings. etc.), recover the
system according to the Recovery Procedure on page
22-27.
After checking and repairing leaks. the system must
be evacuated (see System Evacuation on page 22-451.

Troubleshooting
Tips and Precautions (cont'dl
Insert the connector all the way and make sure it is
securelv locked.
Position wires so that the open end of the cover faces
down.
After installing harness clips, make sure the harness
doesn't interfere with any moving pans.
Keep wire harnesses away from exhaust pipes and
other hot parts. from sharp edges of brackets and
holes, and from exDosed screws and bolts.
V
F6c6op€n end
Handling Wires and Harnosscs
. Secure wires and wire harnesses to the frame with
their respective wire ties at the designated locations,
. Remove clips carefully; don't damage their locks.
Slip pliers under the clip base and through the hole at
an angle, then squeeze the expansion tabs to release the
clrp.
SNAP-BING PLIERS
23-4
NOT GOOO
ll il,/
s*' -.1}8."/_Y--_Y5\
il ,,
Testing and Repairs
o Do not use wires or harnesses with broken insulation.
Replace them or repair them by wrspping the break
with electricaltaoe.
. After installing parts, make sure that no wires arepinched under them.. When using electrical test equipment, follow the
manufacturer's instructions and those described in
this manual.
. lf possible, insert the probe of the tester from the
wire side (except waterproof connector).
. Seat grommets in their grooves properly.
. Use a probe with a tapered tip.
Refer to the instructions in the Honda Terminal Kit for
identification and replacement of connector termi-
nats.

lgnition Switch
4.
Test
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-
1. i/ake sure you have the anti-theft code for the
radio, then write down the frequencies for the
radio's preset buttons ('99 - 00 models).
2. Disconnect the battery negative cable.
3. Remove the driver's dashboard lower cover and
knee bolster (see section 20).
Disconnect the 5P connector from the under dash
fuse/relay box and the 7P connector from the main
wire harness.
Check for continuity between the terminals in each
switch position according to the table.
I I :7P connector
Wire side ot female terminals
BLK/WHT {STIWHT IBAT}
7P CONNECTOR
WHT/BLK
YEL (IG2}BLK/YEL {IG1)
Wire side of female terminals
6. lf the continuity checks do not agree with the table,
replace the electrical switch.
Terminal
Position
1
(ACC)
(3)
(BAT)
5
{tG1) G2)
(1)
(sr)
o (LocK)
| (ACC)o--o
l (oN)o-o
III (START)o--o
1.
Electrical Switch RePlacement
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section \24) belore performing repairs or ser-
vtce.
1. Make sure you have the anti-theft code for the
radio, then write down the frequencies for the
radio's preset buttons {'99 - 00 modelsl.
2. Disconnect the battery negatlve cable.
3. Remove the driver's dashboard lower cover {see
section 20).
Disconnect the 5P connector from the under-dash
fuse/relay box and the 7P connector from the main
wire harness (see left column).
Remove the steering column covers {see section
11t.
lnsert the ignition key, and turn it to "0 {LOCK)".
Remove the two screws and the electrical switch
from the steering lock.
ELECTRICALswtTcH
8. Install in the reverse order of removal.
23-a9

JBrush Holder Test
1. Check that there is no continuity between the O and
o brush holders.
lf there is continuity, replace the brush holder
assemoly.
O BRUSH HOLDER
@ BRUSH HOLDER€) BRUSH HOLDER
2. Insert the brush into the brush holder, and b.ing the
brush into contact with the commutator, then attach
a spring scale to the spring. Measure the spring ten-
sion at the moment the spring lifts off the brush.
SPRING SCALE
Spring Tension
15.7 - 17.7 N (1.60 - 1.80 kgf. 3.5 - 4.0 lbf)
ERUSH
Brush Inspection
Measure the brush length. lf not within the service limit,
replace the brush (or brush holder assembly).
Brush Length
NOTE: To seat new brushes after installing them in their
holders, slip a strip ot #500 or #600 sandpaper. with the
grit side up, over the commutator and smoothly rotate
the armature. The contact surface of the brushes will be
sanded to the same contour as the commutator.
Overrunning Clutch lnspection
Slide the overrunning clutch along the shaft. Does it
move freely? lf not, replace it.
Rotate the overrunning clutch both ways. Does it
lock in one direction and rotate smoothly in
reverse? lf it does not lock in either direction or it
locks in both directions, replace it.
2.
L
Standard (NEW)Service Limit
15.8 - 16.2 mm
(0.62 - 0.64 in)
1 1.0 mm
{0.43 in)
CLUTCH GEAR
DRIVE GEAR

Charging System
Rectifier Removal (cont'd)
Separate the rear housing from the stator/rectifier
assembly by removing the four screws and the ter-minal nut.
TERMINAL NUT
Unsolder the rectifier from the stator leads,. To avoid damaging the diodes with heat, pinch
the stator leads between pliers to carry heat off,and apply the soldering iron only long enough toseparate the leads from the rectifier.. Use a 100 W soldering iron.
STATOR SOLDERING
7. Install the new rectifier in the reverse order of removal.. Apply the soldering iron only long enough toensure a good connection so the heat will notdamage the diodes.
a Use only a rosin core type solder or solder joints
will corrode.
6.
SOLDERING
23-122
Rectifier Test
NOTE: The diodes are designed to allow current to pass
in one direction while blocking it in the opposite direc-tion. Since the alternator rectifier is made up of ninediodes, each diode must be tested for continuity in bothdirections with an ohmmeter that has diode checkinocapability; a total of 18 checks.
1. Check for continuity in each direction between- the B and P terminals.- the B'and P terminals.- E {ground) and the P terminals.
All diodes should have continuity in only one direc-UOn.
lf any of the diodes fails, replace the rectifier assem-bly, (Diodes are not available separately.)

J
9. lMeasure the resistance between the No 1 and No. 2
terminals at E {EMPTY), 112 \HALF FULL) and F
(FULL) by moving the lloat.
USA, Canada-produced {Ceramic board type):
Too ot lhe workbench (Bottom of the fuel tank)
ll the resistance readings are beyond the range. replace
the fuel gauge sending unit
Float PositionE1t2F
Resistance (0)105 - 10829.5 - 35.53.5-5
Jaoan-Ploduced (Wire-wound typel:
Float PositionE1/2F
Resistance (O)105 - 11025.5 - 39.5
Low Fuel Indicator Light Test
NOTE: For the low fuel indicator circuit diagram, refer to
the gauge assembly circuit diagram (see page 23'2311.
1. Check the No. 25 (7 5 A) luse in the driver's under
dash fuse/relay box before testing
2. Park the vehicle on level ground.
3.
4.
Drain the luel into an approved container. Reinstall
the fueltank drain bolt with a new washer.
Add less than 4L (1 1 U.S Gal, 0.9 lmp Gal) of fuel,
and turn the ignition switch ON (ll). The low fuel
indicator light should come on within four minutes'
. lf the light comes on within four minutes, go to
step 8.
. lf the light does not come on within four min-
utes, go to step 5.
Remove the access panel lrom the Iloor'
Turn the ignition switch OFF, then disconnect the
fuel tank sending unit 3P connector.
Connect the fuel tank sending unit 3P terminals No'
1 and No. 3 with a jumPer wire
. lf the light comes on, replace the fuel gauge
sending unit (see Page 23 1421
. lf the light does not come on, check for:
- An open in the GRN/YEL wire between the
fuel gauge sending unit and the fuel gauge
- A blown bulb.- A poor ground (G552)
6.
1.
female terminals
8. Add 4L {1.1 U.S. Gal, 0 9 lmp Gal) of fuel The light
should go off within four minutes.
23-143