Disc HONDA CIVIC 1997 6.G Workshop Manual

Compressor (DENSO)
Replacement
1.lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioning work
for a few minutes, then shut the engine off
Disconnect the negative cable from the battery'
Recover the refrigerant with a recovery/recycling/
charging station lsee page 22-271
Remove the each bolt, then disconnect the suction
and discharge lines from the compressor' Plug or
cap the lines immediately after disconnecting them
to avoid moisture and dust contaminatlon.
6 x '1.0 mm9.8 N.m (1.0 kgf m,7.2 lbfft)
Remove the condenser, but do not disconnect the dis-
charge hose from the condenser (see page 22-441'
Remove the power steering pump belt (see sectron
17]-.
7. Loosen the pivot bolt of the idler pulley bracket and
the adjusting bolt. then remove the A,/C compressor
belt from the pulleys. lf necessary, remove the mount-
ing bolts from the left front mount. then remove the
fuC compressor belt through the gap between the
bodv and the left front mount.
'10 x 1,25 mm4,0 N.m (,1.5 kgf'm. 33 lbt ftl
Disconnect the compressor clutch connector, then
remove the mounting bolts and the compressor'
PIVOT BOLT10 x 1.25 mm4,1 N.m (4.5 kgt'm,33 lbfft)
COMPRESSOR
24 N.m (2.4 kgf m, 17 lbf ftl
(cont'd)
22-37

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
ll.
Tips and Precautions
Bef ore Troubleshooting
. Check applicable fuses in the appropriate fuse/relay
box.
. Check the battery for damage, state of charge, and
clean and tight connections.
. Check the alternator belt tension.
CAUTION:
. Do not quick-charge a battery unless the battery
ground cable has been disconneqted, otherwise you
will damage the alternator diodes.
. Do not attempt to crank the engine with the battery
ground cable loosely connecled or you will severely
damage the wiling,
Handling Connectois
. Make sure the connectors are clean and have no loose
wire terminals.
. Make sure multiple cavity connectors are packed with
grease (except watertight connectors)
. All connectors have push-down release type locks.
Some connectors have a clip on their side used to
attach them to a mount bracket on the body or on
another component. This clip has a pulltype lock.
Some mounted connectors cannot be disconnected
unless you first release the lock and remove the con-
nector from its mount bracket.
LOCKINGPAWL ONOTHERHALF OFCONNECTOR
Pull todrsengage
LOCKING TAB
BRACKET
Never try to disconnect connectors by pulling on
their wires; pull on the connector halves instead
Alwavs reinstall plastic covers.
Before connectang connectors,
nals are in place and not bent.
make sure the terml-
. Check for loose retainer and rubber seals.
RETAINER
The backs of some connectors are packed with
grease. Add grease if necessary. lf the grease is con-
taminated, replace it.
(cont'd)
23-3

Under-dash Fuse/RelaY Box
Removal/lnstallation
SRS components are located in this area. Review lhe
SRS component locations, precautions, and procedures
in the SRS section (24) before performing repairs or ser-
vice.
Removal:
1. Make sure you have the anti-lheft code for the radio
then write down the frequencies lor the radio's pre-
set buttons ('99 - 00 modelsl.
2. Disconnect the battery negative cable. then discon
nect the positive cable, and wait at least three min
utes,
3. Disconnect the airbag connectors (see section 24)'
4. Remove the driver's dashboard lower cover and
knee bolster (see section 20)
5. Remove the two mounting nuts, and pull the under
dash fuse/relay box out from under the dash'
6. Disconnect the connectors from the under-dash
fuse/relay box, and take out the under-dash fuse/
relay box (see section 24).
lnstallation:
1. Connect the connectors to the under-dash tuse/
relay box, then install the under dash fuse/relay box
in the reverse order of removal (see section 24)'
2. Install the driver's dashboard lower cover (see sec
tion 20).
3. Connect the airbag connectors {see section 24)
4. Connect the battery positive cable, then connect the
negative cable.
5. Enter the anti-theft code lor the radio, then enter the
customer's radio station presets ('99 - 00 models)'
6. Confirm that all sYstems work properly'
23-45

Power Relays
Relay Test
Turn Signal/Hazard Relay:
See page 23-172
Normally-open type:
1. Check for continuity between the terminals.. There should be continujty between the No. 1 andNo.3 terminals when power and ground are con-nected to the No. 2 and No. 4 terminals.. There should be no continuity between the No. 1and No. 3 terminals when power is disconnected.
3
. Blower motor relay
. ABS pump motor relay
Terminal
-i*rt"r-*or\13
Disconnected
Connectedo
,I IIY F>rr €,?I
23-86
. Rear window defogger relay
Starter cut relayt '96 - 97 models
Horn relayi '96 97 models
Blower motor high relay: '99 - 0O mooersa

Normally-opsn tYPe:
1. Check for continuity between the terminals
. There should be continuity between the No. 1 and
No. 2 terminals when power and ground are con-
nected to the No. 3 and No 4terminals.
o There should be no continuity between the No 1
and No.2 terminals when power is disconnected'
Terminal
Power iNo.3 - No,4) \
I2
Disconnected
Connectedoo
a
a
a
Power window relaY
Radiator fan relaY
Condenser fan relaY
A/C compressor clutch relaY
Starter cut relay: '98 - 00 models
Horn relay: '98 - 00 models
Five-ierminal type:
1. Check for continuitv between the terminals.
. There should be continuity betlveen the No. 1 and
No. 2 terminals when power and ground are con-
nected to the No. 3 and No 5terminals.
. There should be continuity between the No 2 and
No. 4 terminals when power is disconnected'
--1
I
II
t
Moonroof open relay: '96 - 97 models
Moonroof close relay: '96 - 97 models
(cont'd)
23-87
Terminal
Power (No. 3 - No. 5)\
4
Disconnectedo--o
Connectedo--o

Power Relays
Relay Test (cont'd)
Five-terminsl type:
l. Check for continuity between the terminals.
. There should be continuity between the No. 1and No, 2 terminals when power and ground areconnected to the No. 5 and No. 3 terminals.o There should be continuity between the No. 1and No. 4 terminals when power is disconnected.
. Moonroof open relay: '98-00models
. Moonroof close relay: '98 - 00 mooets
Terminal
P"*"r{ltl"5-N".3)-\14
Disco n n ectedo----o
Connectedo-----o
23-88

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