specification HONDA CIVIC 1999 6.G Service Manual

Opening Drag Check
{Motor Removed)
Before installing the motor, measure lhe effort required
to open the glass using a spring scale as shown.
CAUTION: When using a spring scale, pfotest the lead-
ing edge ol the glass with a shop towel.
lf load is over 40 N (4 kgf,9 lbf), check the side clearance
and glass height (see page 20-51).
SHOP TOWEL
l,e
20-57
Closing Force Check
(Motor Installedl
'1. After installing all removed parts, have a helper
hold the switch to close the glass while you mea-
sure the force required to stop it. Attach a spring
scale as shown. Read the force as soon as the glass
stops moving, then immediately release the switch
and spring scale.
CAUTION: When using a spring scale, protect the
lerding edge ol the glass with a shop towel.
Closing Force: 200 - 290 N(20 - 30 kst, 44 - 66 lbfl
lf the torce in not within specification, install a new
lock washer, adjust the tension by turnang the motor
clutch adjusting nut, and bend the lock washer
against the motor clutch adjusting nut.
LOCKWASHERReplace.
COUNTER.cLocKwrsETo decrease
SCALE

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

A/C System Torque Specifications
O Discharge hose to the compressor (6 x 1.0 mml ............... .. .... ...............' 9.8 N'm {1.0 kgf'm,7.2 lbf'ftl
@ Discharge hose to the condenser {6 x 1.0 mm1................... '... ...... . ......... 9.8 N'm 11.0 kgf'm, 7.2 lbf'ft}
O Condenser pipe to the condenser 16 x 1,0 mm)...............'. . . . ...........'..... 9.8 N'm (1.0 kgl'm, 7.2 lbt'ft)
@ Condensel pipe to the receivel/dryer (5 x 1.0 mml......... ..... . ... . '.......... 9.8 N'm (1.0 kgl'm, 7.2 lbt'ft)
O Receiver pipe A to the leceiver/dryer {6 x 1.0 mm)......... ... .......... .. . . .... 9.8 N'm 11.0 kgf'm. 7.2 lbl'ft)
@ Receiver pipe B to the receiver pipe A 13 N m (1.3 kgf'm, 9.'l lbf'ft)
O Receiver pipe C to the receiver pipe B 13 N m (1.3 kgf'm, 9.4 lbnftl
@ Receiver pipe C to the evaporator {6 x 1.0 mm) ....... 9.8 N'm (1.0 kgf'm, 7.2 lbtftl
O Suction pipe B to the evaporator (6 x 1.0 mml................ . .........'......'....... 9.8 N'm (1.0 kgf m, 7.2 lbf'ftl
e0 Suction pipe A to the suction pipe B ...'. . ...... . ... ...... 31 N'm (3.2 kgt'm, 23 lbf'ftl
O Suction hose to the suction pipe A... ............ . . '......... 31 N'm (3.2 kgl'm, 23 lbf'ft|
@ Suction hose to the compressor (6 x 1.0 mm)................... .. . ... .. ............ 9.8 N'm (1.0 kgf'm' 7.2 lbf'ft|
@@ Compressor to the compressor bracket (8 x 1.25 mm)... ..-........'.'......-.......24 N'm (2 'l kgf'm, 17 lbf ftl
@ Compressor bracket to the cytinder block (10 x 1.25 mml 44 N'm l'1.5 kgf'm, 33 lbf ftl
@ Compressor bracket to the left front engine mounl {12 x 1.25 mm}..... . . . . .. ................. ... ... 59 N'm (6.0 kgf'm, '|i} lbf ftl
22-23

A/C System Service
Performance Test
The performance test will help determine if the air con-
ditioner system is operating within specifications.
Use only service equipment that is U.L.-listed and is cer-
tified to meet the reouirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposure to air conditionor rofrigerant and
lubricant vapor or mist can irrilalo €yes, nose and
throat. Avoid breathing tho air conditioner rstrigerrnt
and lubricant vapor or mist,
lf accidental system discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
compressed air.
@ some mixtur$ of air and R-134a have been
shown lo b9 combustible rt glgvatad pr€ssur63 and can
resull in tire 01 oxplosion causing inlury ot property
damage. Never uao compre33ed air to pressure t99t R-
134a ssrvico 6quipmsnt or vohicla air conditioner sys-
tems.
Additional health and safety information may be obtained
from the refrigerant and lubricant manufacturers.
'1. Connect a R-134a refrigerant recover/recycling/
charging station to the vehicle, as shown, following
the equipment manufacturer's instructions.
2. lnsert a thermometer in the center vent outlet.
Determine the relative humidity and air tempera-
ture,
Test conditions:
. Avoid direct sunlight.
. Open hood.
. Open front doors.
. Set the temDerature control lever or dial to MAX,
COOL, the mode control switch or dial on VENT
and the recirculation control switch on RECIRCU-
LATE.
. Turn the A,/C switch on. and the heater fan switch
on MAX.
. Run the engine at 1,500 rpm.
. No driver or passengers in vehicle
After running the air conditioning for 10 minutes
under the above test conditions, read the delivery
temperature from the thermometer in the dash vent
and the high and low system pressure from the A,/C
gauges.
Recovery/Rocycling/Charging Station
22-24

Clutch InsPection
Check the plated parts of the armature plate for color
changes, peeling or other damage lf there is dam-
age. replace the clutch set.
Check the rotor pulley bearing play and drag by rotat-
ing the rotor pulley by hand Replace the clutch set
with a new one if it is noisy or has excessive play/drag
Measure the clearance between the rotor pulley and
the armature plate all the way around lf the clear-
ance is not within specified limits, the armature plate
must be removed and shims added or removed as
required, following the procedure on page 22-34
Cl€arance: 0.5 ! 0.15 mm {0.020 t 0.006 in)
NOTE: The shims are available in four thicknesses:
0.1 mm,0.2 mm,0.4 mm and 0.5 mm
. Release the field coil connector from the holder' then
disconnect it. Check the thermal protector for conti-
nuity. lf there is no continuity. replace the thermal
protecror,
NOTE: The thermal protector will have no continuity
above 251.6 to 262.4oF 1122lo 128'C). When the tem-
perature drops below 240 8 to 219.8"F (116 to 104"C),
the thermal protector will have continuity
. Check resistance of the field coil
Field Coil Resistance: 3.05 to 3.35 O at 68"F (20"C)
lf resistance is not within specifications, replace the
field coil.
22-33

Compressor (DENSOI
Clutch Inspection
Check the plated parts of the pressure plate for colo.changes, peeling or other damage. lf there is dam-age, replace the clutch set.
Check the pulley bearing play and drag by rotatingthe pulley by hand, Replace the clutch set with a newone if it is noisy or has excessive play/drag.
Measure the clearance between the pullev and thepressure plate all the way around. lf the clearance isnot within specified limits, the pressure plate must beremoved and shim(s) added or removed as required,
following the procedure on page 22-41.
Clearanca:0.5 t 0.15 mm {0.020 r 0.006 in}
NOTE: The shims are availabte in three thicknesses:0.1 mm,0.3 mm and 0.5 mm.
22-40
. Check resistance of the field coil. lf resistance is notwithin specifications, replace the field coil.
Fiald Coil Resistanc€: 3.it to 3.8 O at 20.C l68.Fl

JArmature Inspection and Test
1.Inspect the armature for wear or damage due to con-
tact with the permanent magnet or field winding.
. lf there is wear or damage. replace the armature.
Inspect for damage.
2. Check commutator surface and diameter.
. lf the surface is dirty or burnt. resurface with emery
cloth or a lathe within the following specifications,
or recondition with #500 or #600 sandpaper.
. lf commutator diameter is below the service limit,
replace the armature.
Commutator Diameter
Standard {NEW)Service Limit
28.0 - 28.1 mm
(1.102 - 1.106 in)
27.5 mm
(1.083 in)
VERNIER CALIPEB
3. Measure the commutator runout.
. lf the commutator runout is within the service
limit, check the commutator for carbon dust or
brass chips betlveen the segments.
. lf the commutator runout is not within the ser-
vice limit, replace the armature.
Commutator Runout
Standard (NEW)Service Limit
0 - 0.02 mm(0 - 0.0008 in)
u-u!r mm
(0.002 in)
COMMUTATOR
(cont'd)
23-97

-Performance Test
NOTE: Before staning the following checks. disconnect
the wire from terminal M. and make a connection as
described below using as heavy a wire as possible (prefer-
ably equivalent to the wire used for the car).
Pull-in CoilTest:
Connect the battery as shown, lf the staner pinion pops
out. it is working proPerly.
CAUTION: Do not leavo tho batterv connost€d for more
than 10 seconds.
Hold-in Coil Test:
Disconnect the battery from the M terminal' lf the pinion
does not retract, the hold-in coil is working properly.
CAUTION: Do not loavc lhe battsry connected for mot6
than 10 ssconds.
Retracting Tosi:
Disconnect the battery also from the body. lf the pinion
retracts immediately, it is working properly.
GAUTION: Do not loave the baftery conn€ctod tor more
than 10 seconds.
Startor No-load Tost:
Clamp the starter firmly in a vise.
Connect the starter to the battery as described in
the diagram below, and confirm that the motor
starts and keeps rotating.
1.
3, lf the electric current and motor speed
specifications when the battery voltage is
the starter is working ProPerly.
Specifications:
80 A or less (Electric current),2,600 rpm or more
(Motor-speed)
meet the
at 11.5 V,
23-101

lgnition System
lgnition Coil Test
Using an ohmmeter, measure resistance between the
terminals. lf the resistance is not within soecifications.
replace the ignition coil.
NOTE: Resistance will vary with the coil temperature;
specifications are at 68'F (20'C).
HITACHI:
Primary Winding Resistance
{Betwesn the A and B lerminalsl;
0.45 - 0.55 0
Secondary Winding Resistanc€
(Between the A and secondary winding terminals):
22.1 - 33.6 kA
TERMINAL B {-)
TERMINAL A
TEC:
Primary Winding Resistsnce
{Between the A and B terminalsl:
0.63 - 0.77 0
Secondary Winding Resistance
(Between the A and secondary winding terminals):
12.8 - 19.2 kO
SECONDARYWINDINGTERMINAL
TERMINAL A
23-110
TERMINAL B (-)
lgnition Wire lnspection and Test
CAUTION: Carelully remove the ignition wires bypulling on the rubber boots, Do not bend the wires; you
might break them inside.
'1. Check the condition of the ignition wire terminals. lf
any terminal is corroded, clean it, and if it is broken
or distorted, replace the ignition wire.
Check for broken,corroded, and bentlermrnals.IGNITION WIRE
Connect ohmmeter probes and measure resistance.
lgnition Wire Resistance:
25 k0 max. at 68"F (20"C)
IGNITION WIRE
3. lf resistance exceeds 25 kO, replace the ignition wire.

JRotor Slip Ring Test
1. Check the resistance betlveen the slip rings
There should be 1 8 - 3 0 ohms
. lf resistance meets the specification, go to step 2.
. lf resistance does not meet the specification,
reolace the alternator'
SLIP BINGS
2. Check that there is no continuity between the slip
rings and the rotor or rotor shaft.
3. lf the rotor fails either continuity check, replace the
alternator.
Stator Test
'1. Check that there is continuity between each pair of
leads.
CORE
Check that there is no continuity between each lead
and the coil core.
lf the coil fails either continuity check, replace the
alternator.
ROTOR SHAFT
LEADS
1.
Alternator Brush InsPection
Separate the drive-end housing from the rear hous-
ing as described on page 23-121
Separate the rear housing from the stator/rectifier
assembly by removing the four screws and the ter-
minal nutfrom the rear housing {see page 23-121}
lvleasure the length of the brushes with vernrer
calrpers.
Alternator Brush Length:
O Standard {NEW} @ Service Limit
19.0 mm (0.75 in) 1 5.0 mm (0 20 in)
lf the brushes are less than the service limit, replace
them.
23-123