air conditioning HONDA CIVIC 2003 7.G Workshop Manual

cont'
ItemMeasuremeniOualificationSpecilicationSTEERINGTypeElectric, Power assisted rack and pinion
Overall ratio15.1Turns,lock to-lock
Steering wheel diameter360 mm (14.2 in)SUSPENSIONTypeIndependent srrul with stabiliTer. coil springRearDouble wishboneShock absorberFrontTelescopic, hydraulic. nitrogen gas-frlled
RearTelescopic, hydraulic, nitrogen gas,filledWHEEL
ALIGNMENT
CamberFront0"00'
Bear0.45'
CasterFront1'33'TotaltoeFront0 mm (0 in.)
RearIn 2 mm (1/16 in.)BRAKESType of service brakeFrontPowerassisted self-adjusling ventilated disc
BearPower-assisted self-adjusting solid discType of parking brakeMechanical actuating, rear wheelsPad friction surface areaFront45 cm'(7.0 sq in.)x2
Rear28 cm'(4.3 sq in.) x 2TIRESSize offront and reartiresPl95/60 815 88VSize o{ spare tireT125r0 D15 95MAIR
CONDITIONING
CompressorTypeScroll
Number of
cylinders
Capacity85.7 m015.23 cu in.)/rev.
Maximum speed12,000 rpm
Lubricant capacity130 m0 {4 1/3 floz)
LubricanttypeSP-10 (P/N 38897'P13-A01AH or38899-P13 A01)CondenserTypeCorrugated finEvaporatorTvpeCorrugated fin
BlowerTypeSirocco fan
Motor type220 Wl12 V
Speed control4 Speeo
Maximum capacity480 m" 116.900 cu ft)/hTemperature controlAirmixtype
Compressor clutchTvpeDry, single plate, poly-V belt drive
Electricalpower
cons!mptron at
68"F (20.C)
42 W maximum at 12 V
RefrigerantTypeHFC 134a (R-134a)
Capacity500 550 g (17.6 19.4 oz)
Design Specifications
C
aL
2-12
../ a

Lubricants and Fluids
For details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work
ures {such as Assemoverhaul. lnstallation. etc.) contained in each section.
NO.LUBBICATION POINTSLUBBICANT
1E ng ineHonda Motor Oil (P/N 08798-9023). The oil container
must disolav the API Cenification seal shown below.
Make sure it says "For Gasoline Engines." SAE
Viscositv: See chart below.
2TransmissionHonda MTF*' (P/N 08798-9016)
3Brake svstem (includes ABS line)Honda DOT 3 Brake Fluid*' (P/N 08798-9008)
4Clutch line
5
6
Release fork (manual transmissionl
Throftle cable end (throttle Iink)
Super High Temp Urea Grease {P/N 08798-9002)
7
I
Shift and select cable ends (manual
transmission)
Throttle cable end (dashboard lower panel hole)
Silicone grease
9
10
111'
14
16
17
Brake booster clevis
CIutch booster clevis
Shift lever pivot
Pedal linkage
Battery terminals
Fuel f ill door
Hood hinges and hood latch
Hatch hinges
Door hinoes, uoDer and lower
Multi-purpose grease
18Caliper piston boot, caliper pins and bootsHonda CaliDer Grease (P/N 08C30-80234lvl)
19Air conditioning compressorCompressoroil: SP-10 (P/N 38897-P13-A01AH or
38899-P'13-A01)
For refriqerant; HFC'134 a (R-134 a)
I
Recommond6d Engine OilEngine oilviscosily for amb enttemperalure fanges
-30 -20 -10 0 t0 20
*1:
"2:
Always use Honda Manual Transmission Fluid (MTF). Using motor oii can cause stiffer shifting because it does
not contain the Drooer additives.
Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of
the system.
3-2

Fuel and Emissions Systems
System Descriptions (cont'd)
PGM-FI System
The Programmed Fuel Injection (PGM-Fl) system is a
sequential multiport fuel injection system.
Air Conditioning {A/C) Compressor Glutch Relay
When the ECfM receives a demand for cooling from the
Ay'C system, it delays the compressor from being
energized, and enriches the mixture to assure smooth
transition to the AVC mode.
Air Fuel Ratio lA/Fl Sensor
The Ay'F Sensor operates over a wide airlfuel range. The
Ay'F Sensor is installed upstream of the TWC, and sends
signals to the ECM which varies the duration of fuel
injection accordingly.
SENSORTERMINALS
HEATERTERMINALS
Barometric Pressure {BAROI Sensor
The BARO sensor is inside the ECM. lt convens
atmospheric pressure into a voltage signal that the ECM
uses to modify the basic duration of the fuel injection
discharge.
ztRcoNtaELEMENT
HEATER
11-26
\,
Camshaft Position (CMPI Sensor B (Top Dead Center(TDCI Sensor)
The CMP sensor B (TDC sensor) detects the position of
the No. 1 cylinder as a reference for sequential fuel
injection to each cylinder.
Crankshaft Position (CKPI Sensor
The CKP sensor detects crankshaft soeed and
determines ignition timing and timing for fuel injection
of each cylinder as well as detecting engine misfire.
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a temperature dependent resistor(thermistor). The resistance of the thermistor decreases
as the engine coolant temperature increases.
MAGNET
TERMINAL

A/G Signal Circuit Troubleshooting
Turn the ignition switch ON (ll).
Momentarily connect ECM connector terminals 424
and E18 with a jumper wire several times.
1.
2.
5.
Wire side of female terminals
ls there a clicking noise I rom the NC compressor
clutch?
YES Go to step 3.
NO-Go to step 6.
Sta rt the engine.
Turn the blower switch ON.
Turn the Ay'C switch ON.
Does the NC operate?
YES-The air conditioning signal is OK.I
NO Update the ECM if it does not have the latest
software, or substitute a known-good ECM. then
recheck (see page 11-6). lf the symptom/indication
goes away with a known-good ECM, replace the
original €CM.l
6. Momentarily connect under-hood tuse/relay box
14P connector terminal No. 10 to body ground with
a jumper wire several times.
UNDER.HOOD FUSE/RELAY BOXI4P CONNECTOR
12356
1891011IJ14
ACC (RED)
JUMPER WIRE
Wire side of female terminals
ls there a clicking noise f rom the NC compressor
clutch?
YES- Repair open in the wire between the ECM(E'18) and the Ay'C clutch relay.l
NO- Check the A/C system for other symptoms.l
11-133

21-2
z t-'5
z t-o
z t-o
21-8
21-9
21-10
21-11
21-14
z t- to
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

HVAC {Heating, Ventilation, and Air Conditioning)
SpecialTools
Ret.No.Tool NumberDescriDtion Otv
o07sAz-001000ABackprobe Set 2
---2
att-,,- KCe
/'Tt "-t--'
e^t"'
T
21-2

Heating and Air Conditioning
Component Location Index (cont'dl
CONDENSER FANTest, page 22-51
RADIATOR FAN RELAYTest, page 22-51
Tesl, page 22-51CLUTCH RELAY
MOTOR RELAYTest, page 22-5I
UNDER.HOOD FUSE/RELAY BOX
... A/C PRESSURE SWITCH
RADIATOR FAN
\
.\
-
'-t t_]]l
/l I T I --::--
l- -l -
CONOENSER FAN
21-4

Heating and Air Conditioning
A/C Service Tips and Precautions
Compressed air mixed with R- 134a forms a
combustible vapor.
The vapor can burn or explode causing serious
injury.
Never use compressed air to pressure test
R-134a service equipment or vehicle air
conditioning systems.
Air conditioning refrigerant or lubricant vapor
can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
The air conditioning system uses HFC-134a (R-134a)
ref rigerant and polyalkyleneglycol (PAG) ref rigerant oil,
which are not compatible with CFC'12 (R-12) refrigerant
and mineral oil. Do not use R-'12 refrigerant or mineral
oil in this system, and do not aftempt to use R 12
servicing equipment; damage to the air conditioning
system or your servicing equipment will result.
Use only service equipment that is U.L.-listed and is
certified to meet the requirements of SAE J2210 to
remove R-134a from the air conditioning system.
lf accidental system discharge occurs, ventilate the
work area before resuming service.
R-134a service equipment or vehicle air conditioning
systems should not be pressure tested or leak tested
with compressed air.
Additional health and safety information may be
obtained from the refrigerant and lubricant
manufacturers.
. Always disconnect the negative cable from the
battery whenever replacing air conditioning parts.
. Keep moisture and dirt out of the system. When
disconnecting any lines, plug or cap the fittings
immediately; don't remove the caps or plugs until
iust be{ore you reconnect each line.' Before connecting any hose or line, apply a few drops
of relrigerant oil to the O-ring.. When tightening or loosening a fitting, use a second
wrench to support the matching fitting.. When discharging the system, use a R-'134a
ref rigerant recovery/recycling/charging station; don't
release refrigerant into the atmosphere.
21-6
A: 130 m0 {4 l/3 tl.oz,4.6 lmp.oz)
],^
A/C Refrigerant Oll Replacement
Recommended PAG oil: KEIHIN SP 10:
. P/N 38897-P l3-A01AH: '120 m0 i4 fl oz). P/N 38899-P13'A01: 40 m0 i1 1/3 fl oz)
Add the recommended refrigerant oil in the amount
listed if you replace any of the following parts.
. To avoid contamination. do not return the oilto the
container once dispensed, and never mix it with other
refrigerant oils.. lmmediately af'ter using the oil, reinstallthe cap on
the container, and seal it to avoid moisture
aosorpron.. Donotspill the refrigerant oil on the vehicle; it may
damage the paint. lf it gets on the paint, wash it off
immediately.
Condenser ...........25 mA \516 tl.oz, 0.9 lmp.oz)
Evaporator ........... 45 m0 (1 113Il.oz, '1.4 lmp.oz)
Line or hose ......... '10 m0 {1/3 fl.oz,0.4 lmp.oz)
Receiver/Dryer .... '10 m0 ('113 fl.oz,0.4 lmp.oz)
Leakage repai r .... 25 m0, 1516 Il oz, 0.9 lmp.oz)
Compressor ......... For compressor replacemenl,
subtract the volume of oil drained
from the removed compressor from
130 m0 (4 1/3fl.oz, 4.6lmp.oz), and
drain the calculated volume of oil
f rom the new compressor: '130 m0
i.4113 fl.oz,4.6 lmp.oz) Volume of
removed compressor = Volume to
drain from new compressor.
NOTE: Even if no oil is drained from
the removed compressor, don't
d rain more than 50 m0 \1 2/3 fl.oz,'1.8 lmp oz)from the new
compressor.
\
REMOVEDCOMPBESSOR
rA
li
\.. rJ
b
I
,lEL.-
"o*t ttu"
NEWCOMPRESSOR
/- a\i tl
r/
\:)-) -/
_ 0L'r:l_
I I I DRAINING_*lH I voLUME

Heating and Air Conditioning
General Troubleshooting Information
How to Retrieve a DTC
The heater control panel has a self-diagnosis function. To run the self-diagnosis function, do the following:
1. Turn the fan switch OFF.
2. Pressand holdthe recirculation control switch andthe rear window defoooer switch down.
3. Turn the ignition switch oN {lli.
4. Release both switches. The recirculation indicator and the rear window defogger indicator come on. The
recirculation indicator goes off 3 seconds later and the Ay'C indicator comes on. then the self-diagnosis will begin.
About 10 seconds later, the self-diagnosis will finish and the A,/C indicator goes off.
.lfanytroubleisfound.therecirculationindicatorblinksthediagnostictroublecode(DTC)toindicateafaulty
circuil or comDonent.. lf the system is OK, the recirculation indicator stays off.
atc
@r
RECIRCULATIONCONTROL SWITCH
BECIRCULATIONINDICATOB
/A\
-:@
INOICATOR
REAR WINDOWOEFOGGER INDICATOR
REAR WINDOWDEFOGGER SWITCH
Examole of DTC indication Pattern IDTC 7)
DTC 7
Reseiting the Selt-diagnosis Function
Turn the ignition switch OFF to cancel the self-diagnosis function. After completing repair work, run the self-diagnosis
function aoain to make sure thatthere are no other malfunctions.
Recirculation +indicatot
Recirculation +indicalorgo6s oft----->
21-8

Heating and Air Conditioning
{
a
a
SvmptomDiagnostic procedureAlso check for
Recirculation control doors do not
change between Fresh and Recirculate
Recirculation Control Motor
Circuit Troubleshooting (see page
21 251
Cleanliness and tightness of all
connectors
Both heater and Ay'C do not workHeater Control Power and Ground
Circuits Troubleshooting (see
page 21-27)
Blown fuse No. '14 (10A) in the
under-dash fuse/relay box
Poor ground at G501
Cleanliness and tightness of all
conneclors
Condenser fan does not run at all (but
radiator fan runs with the Ay'C on)
Condenser Fan Circuit
Troubleshooting {see page 21-28)
. Poor ground at G301. Cleanliness and tightness of all
connectors
Both fans do not run with the A,/C onRadiator and Condenser Fans
Common Circuit Troubleshooting
(see page 21-29)
Blown fuse No. 1 (20A) and No.4
(20A) in the under-hood fuse/relay
box
Poor ground at G30l
Cleanliness and tightness of all
connectors
Compressor clutch does not engage(both fans run with A,/C on)
Compressor Clutch Circuit
Troubleshootinq (see Daqe 21-30)
Cleanliness and tightness of all
connectors
A/C system does not come on (both
fans and compressor)
Ay'C Pressure Switch Circuit
Troubleshooting (see page 21-32)
Blown fuse No. 1 (20A) and No. 4
(20A) in the under-hood fuse/relay
box
Poor ground at G301
Cleanliness and tightness of all
connectors
\Symptom Troubleshooting Index
\
21-10
!