evap HONDA CIVIC 2003 7.G Service Manual

EVAP System
DTC Troubleshooting (cont'dl
31. While monitoring FTP sensor voltage with theHonda PGM Tester, or measuring voltage betweenECM connector terminals E4 and E14, slowly pump
the vacuum oumD.
ECM CONNECTOR E 13lPI
Wire side ot female terminals
32. Continue to pump vacuum until the voltage drops
to about 1.5 V. Make sure the engine coolant
temperature is still above 95'F 135.C) and your
vacuum pump has no leak.
33. Monitor the voltage for 20 seconds.
Does the voltage drop 1.5V and hold for at least
20 seconds?
YES Inspect the EVAP canister vent shut valve
line and connections.l
NO-Go to step 34.
34. Turn the ignition switch OFF.
35. Discon nect the quick-con nect fitting (A) fromthe
EVAP canister, and plug the canister port {B).
36. Turn the ignition switch ON (ll).
11-184
42. Turn the ignition switch ON (ll).
I
38.
39.
37. While monitoring FTP sensor voltage with theHonda PGM Tester, or measuring voltage betweenECM connector terminals E4 and E 14, slowly pump
the vacuum pump.
ECM CONNECTOR E {31PI
Wire side of lemale terminals
Continue to pump vacuum until the voltage drops
to about 1.5V. Make sure the engine coolant
temperature is still above 95"F (35"C) and your
vacuum pump has no leak.
Monitor the voltage for 20 seconds
Does the voltage hold for at least 20 seconds?
YES Inspecl the fuel tank vapor control lineand
connections.I
NO Go to step 40.
Turn the ignition switch OFF.
Disconnect the purge line hose {A) from the
canister at the metal line and plug the hose (B).
40.
41.

43. While monitoring FTP sensor voltage with the
Honda PGM Tester, or measuring voltage between
ECM connector terminals E4 and E14, slowly pump
the vacuum pump.
ECM CONNECTOR E {31P)
Wire side of female terminals
Continue to pump vacuum until the voltage drops
to about 1.5V. Make sure the engine coolant
temperature is still above 95'F (35'C) and your
vacuum pump has no leak.
Monitor the voltage continuously for 20 seconds.
Does the voltage drop to 1.5 V and hold f or at
least 20 seconds?
YES Inspect the EVAP canister purge valve line
and connections. lf they are OK, perform the EVAP
two way valve test (see page 11-186) and the fuel
tank vapor control valve test (see page 1'l-187) l
NO-Replace the EVAP canister
(see page 11-189).1
44.
45.
11-185

EVAP System
EVAP Two Way Valve Test
Special Tools Required. Vacuum pump/Gauge,0-30 in. Hg
A973X-041-XXXXX. Vacuum/Pressure cauge.0-4 in. Hg 07JAZ-0010008
1. Remove the fuelfill cap.
2. Disconnect the vapor line from the EVAP two wayvalve (A). Connect it to a T-fitting (B) from thevacuum gauge and the vacuum pump as shown,
07JAZ-0010008
Apply vacuum slowly and continuously while
watching the gauge. The vacuum should stabilize
momentarily at 0.8 2.1 kPa (6 16 mmHg,
0,2 0.6 in.Hg).
lf the vacuum stabilizes {valve opens) below 0.8 kpa(6 mmHg,0.2 in.Hg) or above 2.1 kPa (16 mmHg,
0.6 in.Hg), install a new valve and retest.
11-186
4. Move the vacuum pump hose from the vacuumfitting to the pressure fitting, and move the vacuumgauge hose from the vacuum side to the pressure
side (A) as shown.
Slowly pressurize the vapor line while watching thegauge. The pressure should stabilize momentarilV
above 1.0 kPa (8 mmHg, 0.3 in.Hg).
. lfthe pressure momentarily stabilizes (valve
opens) above 1.0 kPa (8 mmHg,0.3 in.Hg), thevalve is OK.. lf the pressure stabilizes below 1.0 kPa (8 mmHg,
0.3 in.Hg), install a new valve and retest.

FuelTank Vapor Control Valve Test
Special Tools Required
Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX
Float Test
1. Make sure the fuel tank is less than half full.
2. Remove the fuel fill cap to relieve fuel tank
pressure, then reinstall the cap.
3. Disconnect the fuel tank vapor recirculation tube
{A), and connect a vacuum PumP to it.
Plug the line (B).
Apply vacuum to the fuel tank vapor recirculation
tuDe.
lf the vacuum holds, replace the fuel tank vapor
control valve (see page 11-189).
lf the vacuum does not hold, the float is OK. Do
the valve test.
5.
A973X-041-XXXXX
Valve Test
1. N4ake sure the fuel tank is less than half full
2. Remove the fuel fill cap.
3. Disconnect the fuel tank vapor signal tube (A).
Disconnect the vacuum hoses (A) from the EVAP
canister (B), then plug the ports with plugs (C)4.
A973X-O41-XXXXX
5. Disconnect the vacuum hose (D) from the EVAP
canister vent shut valve (E), and connect a vacuum
pump to the vacuum hose.
6. Pump the vacuum pump 80 times.
. lf the vacuum holds, goto steP 7.. lf the vacuum does no1 hold, go to step 10.
(cont'd)
11-187

EVAP System
FuelTank Vapor ControlValve Test (cont'd)
7. Connect a second vacuum pump to the fuel tankvapor signaltube (A).
8. Apply vacuum (1 pump) to the fuel tank vaporsignal tube (A). then check the vacuum on thepump in step 6.
. lf the vacuum holds, replace the fueltank vapor
control valve {see page 11-189).. If the vacuum is released, goto step 9.
11-188
10.
Fill the fuel tank with fuel, then check for fuel in theEVAP two way valve (A), and fuel tank vaporrecirculation hose (B).
NOTE: At either location, tiny droplets of fuel arenormal.
. lf fuel runs out of th e hoses at either location,
replace the fuel tank vapor control valve..lfthefuel does not run out of the hoses, the fuel
tank vapor system function is normal.
Disconnect the fuel tank vapor quick disconnectfrom the EVAP canister, then plug lhe port on the
canister. Reapply vacuum (80 pumps).
. lf the vacuum holds, replace the fuel tank control
valve (see page 1 1-189).. lf the vacuum does not hold, insDect the EVAP
canister vent shut valve o-ring. lf the o-ring is OK,replace the EVAP canister, and repeat step 4.
Check for fuel rirnning out.
Check for fuel running out.

EVAP Canister Replacement
l. Remove the vacuum hoses (A).
2. Remove the boit (B).
3. Remove the EVAP canister (C).
4. Install in the reverse order of removal.
Fuel Tank Vapor Control Valve
Replacement
1. Remove the fuel tank(seepagell-155).
2. Remove the fueltank vapor control valve(A) from
the fuel tank (B).
Install the fuel tank vapor control valve.
Install the fuel tank (see page 1 'l -155).
3.
4,
11-189

19. Tighten the front engine mount bracket mounting
bolt.
'12 x 1.25 mm64 N.m 16.5 kgf.m,il7 lbf.ft)
20. Install the splash shield.
21. lnstallthe brake booster and EVAP line bracket
mounting bolts (A). and air cleaner housing bracket
mounting bolt (B). Tighten the air cleaner housing
bracket mounting bolt (C), and install the water
pipe mounting bolt (D).
A9.8 N.m(1,0 kqf
%,
'B
22 N.ml2.2kgl m,16 rbt.ft)
9.8Nm(1.0 kgf m.7.2 tbl{rl
22.
22Nm{2.2 kgf m, 16 lbf ft)
Installthe engine harness cover.
(cont'd)
13-11

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z t-'5
z t-o
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21-14
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HVAC (Heating, Ventilation, and Air Gonditioningl
Heating and Air Conditioning
SpecialTools
Comoonent Location lndex ........
A/C Service Tios and
Precautions
A,/C Refrigerant Oil
ReDlacement
General Troubleshooting
lnformation
DTC Troubleshooting Index .......
Symptom Troubleshooting
1ndex..............
System Description .....................
Circuit Diagram
DTC Troubleshooting ..................
Recirculation Control Motor
CircuitTroubleshooting .......... 21-25
Heater Control Power and Ground
Circuits Troubleshooting ........ 21-27
Condenser Fan Circuit
Troubleshooting ...................... 21-28
Radiator and Condenser Fans
Common Circuit
Troubfeshooting ...................... 21-29
Compressor Clutch Circuit
Troubleshooting ...................... 21-30
A,/C Pressure Switch Circuit
Troubleshooting ...................... 21-32
Air Mix Control Motor
Test and Reolacement ............. 21-34
Mode Control Motor
Test and Replacement ............. 21-35
Recirculation Control Motor
Test and Reolacement ............. 21-36
Evaporator Temperature Sensor
Reolacement and Test ............. 21-31
Power Transistor Test ................. 21 -38
Heater Control Panel and
Push Switch Assemblv
Removal and Installation ........ 21-38
Dust and Pollen Filter
Reolacement ..21-39
Blower Unit Removal and
lnstallation ...... 21-39
Blower Unit Comoonents
ReDlacement ............................ 21-41
Evaporator Core
Reolacement ..21-42*Heater Unit/Core
ReDlacement ..21-43
Heater Valve Cable
Adjustment .....21-46
CompressorReplacement .......... 21-47
Comoressor Clutch Check .......... 21-48
Comoressor Clutch Overhaul ..... 21-49
Compressor Thermal Protector
Reo1acement ............................ 21-51
Comoressor Relief Valve
Reolacement ............................ 21-51
Condenser Reolacement ............ 21-52
Refrigerant Recovery .................. 21-53
System Evacuation ...................... 21-54
System CharginS ......................... 21-55
Refrigerant LeakTest .................. 21-56
A,/C Svstem Tests ........................ 21-57

Heating and Air Gonditioning
Component Location Index
SERVICE VALVE{LOW.PRESSUBE SIDEI
EVAPORATOR CORE(Built-in the heater unit)Beplacement, page 21 42
COMPRESSORBeplacement, page 21 47Clutch Check, page 21-48Clutch Overhaul, page 21-49Thermal Protector Check, page 21-48Thermal Protector Replacement, page 21 51Relief Valve Replacement, page 21 51
SERVICE VALVE{HIGH-PRESSURE SIDEI
RECEIVER/DRYER
CONOENSEBReplacement, page 21-52

HEATER UNIT/COREBeplacement, page 21-43
BLOWEN UNITRemoval and Installation, page 21-39
HEATER VALVE CABLEAdjustment, page 21-46
BLOWER UNIT COMPONENTSReplacement, page 21-41
DUSTAND POLLENFILTERReplacement, page 21'39
RECIRCULATION CONTROL MOTORTest, page 21-36Replacement, page 21-36
MODE CONTROL MOTORTest, page 21-35Replacement, page 21-35
AIR MIX CONTROL MOTORTest, page 21'34Replacement, page 21'34
POWER TRANSISTORTest, page 21-38
HEATER CONTROL PANELRemovaland Installation, page 21 38
PUSH SWITCH ASSEMBLYRemoval and Installation, page 21'38EVAPORATOR TEMPERATURESENSORReplacement, page 21-37Test, page 21-37
21-5