oil HONDA INTEGRA 1998 4.G Workshop Manual

A/C System Service
Recovery
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 rclrigerant
and lubricant vapor o. 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 Dressure tested or leak tested with
compressed air.
@ some mixtures of air and R-134a have
been shown to be combustible at €levated pros3ures
and can result in lire or explosion causing iniury or
plop€rty damage. Never use comprossgd air to pressure
iest R-134a service equipment or vehicle air conditioner
sYstsms.
Additional health and safety information may be
obtained from the refrigerant and lubricant manufac-
tures,
Connect a R-134a refrigerant Recovery/Recycling/
Charging System to the vehicle. as shown, follow-
ing the equipment manufacturer's instructions.
Measure the amount of refrigerant oil removed
from the IVC system after the recovery process is
completed.
NOTE: Be sure to install the same amount of new
refrigerant oil back into the A/C system before
charging.
Recov€ry/Recycling/Cha.ging Systom.
HIGH.PRESSURESIDE
't.
22-22

J
Pressure Test Chart
Performance Test on page 22.24.
TEST RESULTSRELATED SYMPTOMSPROBABLE CAUSEREMEDY
Discharge (highlpressure
abnormally high
After stopping compressor, pressure
drops about 200 kPa (2.0 kgflcm',28psi) quickly, and then falls gradually.
Air in systemRecover, evacuate and rechargewith specified amount.Evacuation: see pag€ 22-38Charging: see page 22-39
Reduced or no air tlow throughconoenser.
. Clogged condenser orradiator fins. Condenser or radialor fannot working proPerly
CleanCheck voltage and fan rpmCheck fan direction
Line lo condenser is excessively hot.Restricted flow of felrigerantin systemRestricted lines
Dischargepressureabnormally low
High and low pressures are balancedsoon after stopping compressor. Lowside is higherthan normal.
. Faulty compressordischarge valve. Faulty compressor seal
Replace the compressor.
Outlet of expansion valve is notfrosted, low pressure gauge
indicates vacuum.
. Faulty expansion valve. lvloisture in system
. Replace. Recover, evacuate and rechargewith specified amount.
Suction (low)pressure
abnormally low
Expansion valve is not frosted andlow-pressure line is not cold. Lowpressure gauge indicates vacuum.
Frozen expansion valveFaulty expansion valveReplace the expansion valve.
Discharge temperature is low and theairflow from vents is restricted.Frozen evaporatorRun the fan with compressor off,then check A,/C thermostat.
Expansion valve is frosted.Clogged expansion valveClean or replace.
Receiver/dryer outlet is cool and inletis warm (should be warm duringoperal|onJ.
Clogged receiver/dryerReplace
Suctionpressureabnormally high
Low-pressure hose and seryicevalve are cooler than the temPera-ture around evaporator.
Expansion valve open toolongLoose expansion capillarytube
Repair or replace.
Suction pressure is lowered whencondenser is cooled by water.Excessive refrigerant insystemRecover. evacuate and rechargewith specified amount.
High and low pressure are equalizedas soon asthe compressor asstopped, and both gauges fluctuatewhile running.
Faulty gasket
Faulty high-pressure valveForeign panicle stuck in highpressure valve
Reolace the comDressor.
Suction and dis-charge pr€ssuresabnormally high
Reduced air flow throughcondenser.
. Clogged condenser orradiator fins. Condenser or radiator lannot working properly.
Clean condenser and radiatorCheck voltage and fan rpmCheck fan direction
No bubbles in sight glass whencondenser is cooled bv water.Excessive refrigerant in systemRecover. evacuate and rechargewith specified amount.
Suction anddischargepfessure
abnormally low
Low-pressure hose and metal endareas are cooler than evaDorator.Clogged or kinked lowpressure hose partsRepair or replace.
TemP€rature around expansionvalve is too low compared with thataround receiv€r/dryer.
Clogged high-pressure lineRepair or replace.
RetrigerantleaksCompressor clutch is dirty.Compressor shaft seal leakingReplace the compressor.
Comoressor bolt(s) are dirty.Leaking around bolt(s)Tighten bolt{s) or replacecompressor.
Compressor gasket is wet with oil.Gasket leakingReolace the comoressor.
22-23

Evaporator
Replacement
Cut the dashboard insulato. at the areas shown.
Disconnect the connector from the A,,/C thermostat.
and remove the wire harness clips from the evapo-
rator.
6 x 1.0 rnm9.8 N.m 11.0 kgf.m,7.2 tbl.ft)
EVAPOBATOB
7. Remove the four self-tapping screws. the mounting
bolt and the mounting nut.
8. Disconnect the drain hose, and remove the evapo-
rator.
9, Install in the reverse order of removal, and:
. if you're installing a new evaporator, add refrig-
erant oil (ND-OlL 8: PiN 38897 - PR7 - A0IAH or
38899 - PR7 - A0 I I lsee page 22-21) .. replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them.
NOTE: Be sure to use the right O-rings tor HFC-
134a (R-134a) to avoid leakage.
. apply sealant to the grommets.
. make sure that there is no air leakage.. charge the system (see page 22-39) and test itsperformance {see page 22-24l.
CLIPS
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section {23) before performing repairs or ser-
vice.
1. Recover the retrigerant with a Recovery/Recycling/
Charging System \see page 22-221.
2. Remove the bolts, and disconnect the receiver line
and the suction line from the evaporator.
NOTE: Plug or cap the lines immediately after dis-
connecting to avoid moisture and dust contamina-
UOn.
6x1.0mm9.8 N.m 11.0 kgf.m,1.2 tbi.ft)
Remove the glove box (see section 20).
Remove the four bolts and the glove box frame.4.
SUCTION LINE
RECEIVER LINE
22-26

J
Overhaul
Pull out the A,/C thermostat sensor from the evapo-
rator fins.
t
I
ir
I
Remove the self-tapping screws and clamps from
the housing.
3. Carefully separate the housings and remove the
evaporator.
4. lf necessary. remove the expansion valve.
NOTE: When loosening the expansion valve nuts,
use a second wrench to hold the expansion valve or
evaporator pipe. Otherwise, they can be damaged.
Assemble in the reverse order of disassembly.
Make note ot these items:
Replace the O-rings with new ones at each fit-
ting, and apply a thin cost of retrigerant oil (ND-
OIL 8: P/N 38897 - PR7 - A01AH or 38899 - PR7 -
A01) before installing them.
NOTE: Be sure to use the right O-rings for HFC-
134a (R-134a) to avoid leakage.
Install the expansion valve capillary tube with
the capillary tube in contact with the suction line
directly, and wrap it with tape.
Reinstall the Ay'C thermostat sensor to its original
location.
TAPEReplace.Make sure there is no foreign matter stuck between
tEVAPORATORblow dirt out of tinswith compressed alr'8 N.m {0.8 kgt'm.6 rbf.ftl
CAPILLARY TUBE
EXPANSION VALVE
24 N.m (2.{ kgtm.17 rbf.ftl
UPPER HOUSING
%
6th tin f.om outlet sido
A/C THERMOSTATTest, page 22'19
EVAPORATOR LID
22-27

This compressor is a Nippondenso piston type compressor for HFC-134a (R-134a). A revolving inclined disc drives the sur-rounding 10 reciprocating pistons. As the inclined disc revolves, it pushes the pistons, ,protected by a ceramic shoe, thuscompressing the refrigerant.
FIELD COIL
ar:o@
o-> @ ______-__> o,_______> @
r____________l
Compressor
Description
\
22-28

lllustratedlndex
CLUTCHSETlnspection,Page 22-32
SNAP RING AReplace.
FIELD COILInspection, page 22-32
I / COMPRESSOR COMPLETE
.-- lDo not disassemble)
SUCTION SERVICE VALVEO.RINGReplace.
I
S..-
VX
I
I ^.-{\
I.ory
O.RINGReplace.RELICF VALVER€placement. page 22-34
22-29

J8. Remove the four bolts and the suction servtce valve
from the compressor.
25.s18.8 tbf.ft)N.m {2.6 kgt.m,
A\
-/ l=\'zI
i:-
9.
SUCTION SERVICEVALVE
O-RING \Benrace. --'.l4p
lf necessary, remove the compressor bracket as fol
- Remove the engine mount nut and the washer'
NOTE: When tightening the engane mount nut,
make sure the washer is set properly on the left
front engine mount as shown.
- Remove the four mounting bolts and the com-
pressor bracket.
LEFT FRONTENGTNE MOUNT 12 x 1.25 mm
I
69 N.m {7.0 kg{.m.s1 rbt.ft)
10 x 1.25 mm47 N.m (4.8 kgf.m.35 rbf.ftt
10. lnstall in the reverse order of removal. Make note of
these rtems:
) lf you're installing a new compressor, drain all
the refrigerant oil from the removed compressor,
and measure its volume, Subtract the volume of
drained oil from 140 m{ 14 2/3ll.oz,4.93 imp.oz);
the result is the amount of oil you should drain
from the new compressor (through the suction
{itting).
r Replace the O-rings with new ones at each fit-
ting, and apply a thin coat of refrigerant oil
before installing them.
NOTE: Be sure to use the right O-rings for HFC-'t34a (R-134a) to avoid leakage.
. use refrigerant oil (ND-OlL 8: P/N 38897 PR7-
A0IAH or 38899 - PR7 - A01) for R-'134a DENSO
piston type compressors onlY.
. To avoid contamination, do not return the oil to
the container once dispensed, and never mix it
with other refrigerant oils.
. lmmediately after using the oil, replace the cap
on the container, and seal it to avoid moisture
aDsorDt|on.
. Do not spill the refrigerant oil on the vehicle; it
may damage the paint; if the refrigerant oil con-
tacts the Daint, wash it off immediately.
. Do not damage the radiator fins when installing
the condenser fan shroud and the compressor.
. Adjust the Ay'C compressoi belt {see page 22-36J
. Adjust the power steering pump belt (see section
17J.
. Charge the system (see page 22-39) and test its
performance {see Page 22-24).
WASHER
22-31

Compressor
Clutch Inspection
Check the plated parts of the pressure plate for color
changes, peeling or other damage. lf there is dam-
age, replace the clutch set.
Check the pulley bearing play and drag by rotating
the 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 Dullev and thepressure plate all the way around. lf the clearance is
not within specified limits, the pressure plate must beremoved and shims added or removed as required,following the procedure on page 22-33.
Clearanca: 0.50 t 0.15 mm (0.020 r 0.006 in)
NOTE; The shims are available in three thicknesses:
0.1 mm, 0.3 mm and 0.5 mm.
22-32
Check resistance of the field coil.
Field Coil Resistance: 3.6 1 0.2 ohm at 68'F {20'C)
lf resistance is not within specifications, replace the
field coil.

Compressor
a
a
Clutch Overhaul (cont'dl
Remove the screw from the field coil ground termi,
nal. Remove snap ring A with snap ring pliers, then
remove the field coil.
. Be careful not to damage the field coil and com-presso. during removal/installation.
. Once snap ring A is removed, replace it with a
SNAP RING AReplace.
5. Install in the reverse order of removal, andl
install the field coil with the wire side facing
down (see above).
clean the pulley and compressor sliding surfaceswith non-petroleum solvent.
check the pulley bearings for excessive play.
make sure the snap rings are in the groove prop-
efly.
apply locking agent to the threads of the center
bolt, and tighten it securely.
make sure that the pulley turns smoothly after
it's reassembled.
Relief Valve Replacement
Recover the refrigerant with Recovery/Recycling/
Charging System lsee page 22-221.
Remove the relief valve and the O-ring. Plug the
opening to keep foreign matter from entering the
system and the compressor oil from running out,
NOTE:
. Do not let the compressor oil run out.
. Make sure there is no foreign matter in the sys-
tem.
RELIEF VALVE13.2 N.m (1.35 kgf.m,9.76lbtft)
3. Clean the mating surfaces.
4. Replace the O-ring with a new one at the relief
valve, and apply a thin coat of refrigerant oil (ND-
OIL 8: P/N 38897-PR7-A01AH or 38899-PR7-A01)
before installing it.
5. Charge the system (see page 22-39), and test itsperformance (see page 22-241.
6. Check for leaks, and insert the cap in the top of the
FIELD
t\I lu
B _t_:---\-lr
\,/
22-34

Condenser
J
Replacement
RADIATOR UPPERMOUNT BRACKETS
Recover the refrigerant with a Recovery/Recycling/
Charging System lsee page 22-221.
Remove the coolant reservoir.
NOTE: Do not disconnect the reservoir hose from
the coolant reservoir and the radiator.
Remove the bolts and the radiator upper mount
brackets. then remov6 the boll from the suction
hose bracket.
COOLANT RESERVOIR
6x1.0mm9.8 N'm 11.0 kgf'm, ?.2lbf'ft)
4. Remove the bolts, then disconnect the discharge
line and the condenser line from the condenser.
NOTE: Plug or cap the lines immediately after dis-
connecting them to avoid moisture and dust con'
tamination.
DISCHARGE LINE
6x1.0mm9.8 N.m {1.0 kgj'm, 7.2 lbl'ft)
5. Remove the two mounting bolts, then lift out the
condenser as shown.
NOTE: Be careful not to damage the radiator and
condenser fins when removing the condenser.
6x1.0mm9.8 N m 11.0 kgf m, 7.2 lbf ft)
lnstall in the reverse order of removal. Make note of
these items;
. lf you're instslling a new condenser, add refriger-
ant oil (ND-olL 8: P/N 38897-PR7-A01AH or 38899- PR7 - A01) (see page 22-211.
. Replace the O-rings with new ones at each fit-
ting, and apply a thin coat of refrigerant oil
before installing them.
NOTE: Be sure to use the right O-rings for HFC-
134a (R-1344) to avoid leakage.
a Do not damage the radiator and condenser fins
when installing the condenser.
o Be sure to install the condenser mount cushions
securely into the holes.
. Charge the system {see page 22-39) and test its
performance (see page 22-241.
CONOENSER LINE
22-37