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02-03 Honda Civic Si Service Manual

1. 21 39 Blower Unit Removal and Installation 21 39 Blower Unit Components Replacement 21 41 Evaporator Core Replacement 21 42 Heater Unit Core Replacement 21 43 Heater Valve Cable Adjustment Compressor Replacement Compressor Clutch Check Compressor Clutch Overhaul 21 49 Compressor Thermal Protector Replacement 21 51 Compressor Relief Valve Replacement 21 51 Condenser Replacement Refrigerant Recovery System Evacuation System Charging 21 55 Refrigerant Leak Test 21 56 System Tests 21 57 HVAC Heating Ventilation and Air Conditioning Special Tools Ref No Tool Number Description D 07SAZ 001000A Backprobe Set 2 5 0 21 2 Heating and Air Conditioning e Component Location Index EVAPORATOR CORE SERVICE VALVE Built in the heater unit LOW PRESSURE SIDE Replacement page 21 42 SERVICE VALVE HIGH PRESSURE SIDE RECEIVER DRYER COMPRESSOR eplacement page 21 47 Clutch Check page 21 48 CONDENSER 21 52 Clutch Overhaul page 21 49 eplacement page Thermal Protector Check page 21 48 Thermal Protector Replacement page 21 51 Relief Valve Replacement page 21 5
2. 21 29 Heating Air Conditioning Radiator and Condenser Fans Common Circuit Troubleshooting cont d Compressor Clutch Circuit Troubleshooting 1 Check the 1 204 fuse in the under hood 9 Using a Backprobe Set measure the voltage between the No 6 terminal of ECM connector B 24 and body ground with the ECM connectors connected ECM CONNECTOR B 24P Wire side of female terminals 15 there battery voltage YES Update the ECM if it does not have the latest software or substitute a known good ECM then recheck see page 11 6 If the symptom indication goes away with a known good ECM replace the original NO Repair open in the wire between the radiator fuse relay box and the No 14 10A fuse in the under dash fuse relay box Are the fuses OK YES Go to step 2 NO Replace the fuse s and recheck IM 2 Check the engine coolant temperature the throttle position sensor and the idle speed use the Honda PGM Tester PGM FI data list if possible Is the coolant temperature above nomal the throttle position sensor reading too high or the idle speed too low YES Troubleshoot and repair the cause of the high engine coolant temperature high throttle position sensor reading or low idle speed li to step 3 3 Remove the compressor clutch relay from the under hood fuse relay box and test it see page 22 51
3. EVAPORATOR TEMPERATURE SENSOR 2P CONNECTOR Wire side of female terminals 3 Disconnect heater control panel connector 22 4 Check for continuity between the No 7 terminal of 18 there continuity heater control panel connector 22 and body ground YES Check for loose wires or poor connections at heater control panel connector 14P and B 22P HEATER CONTROL PANEL CONNECTOR B 22P and at the evaporator temperature sensor 2P connector If the connections are good substitute a known good heater control panel and recheck If the symptom indication goes away replace the 5 gt lt original heater control panel M NO Repair open the wire between the heater control panel and the evaporator temperature sensor W Wire side of female terminals Is there continuity YES Repair short to body ground in the wire between the heater control panel and the evaporator temperature sensor NO Substitute a known good heater control panel and recheck If the symptom indication goes away replace the original heater control panel 21 24 Recirculation Control Motor Circuit Troubleshooting 1 Check the 14 10A fuse in the under dash fuse 8 Check for continuity between the No 5 and No 6 relay box terminals of heater control panel connector A 14P and body ground individually Is the fuse OK HEATER CONTROL PANEL CONNECTOR A 14 YES
4. Go to step 2 NO Replace the fuse and recheck IN 2 Disconnect the recirculation control motor 5P connector 3 Turn the ignition switch ON Il 4 Measure the voltage between the No 5 terminal of the recirculation control motor 5P connector and Wire side of female terminals body ground RECIRCULATION CONTROL MOTOR Is there continuity 5P CONNECTOR YES Repair any short to body ground in the wire s between the heater control panel and the recirculation control motor lilt BLK YEL NO Go to step 9 10 e 9 Turn the ignition switch ON II and check the same wires for voltage Wire side of female terminals HEATER CONTROL PANEL CONNECTOR A 14P Is there battery voltage YES Go to step 5 NO Repair open in the wire between the No 14 fuse in the under dash fuse relay box and the recirculation contro motor W 5 Turn the ignition switch OFF Wire side of female terminals 6 Testthe recirculation control motor see page 21 36 Is there any voltage Is the recirculation control motor OK YES Repair any short to power in the wire s between the heater control panel and the YES Go to step 7 recirculation control motor This short may also damage the heater control panel Repair the short NO Replace the recirculation control motor or to power before replacing the heater control repair the linkage and doors panel W LN e 7 Disconnect heater control pa
5. WIRE 8 Connect No 1 and No 3 terminals of power transistor 4P connector with jumper wire Wire side of female terminals POWER TRANSISTOR 4P CONNECTOR 3 Turn the ignition switch ON Il BLU BLK Does the blower motor run JUMPER YES Go to step 4 WIRE NO Go to step 17 BLK 4 Turn the ignition switch OFF Wire side of female terminals 5 Disconnect the jumper wire 6 Disconnect the power transistor 4P connector 9 Turn the ignition switch ON II Does the blower motor run at high speed YES Go to step 10 NO Repair open in the wire between the power transistor and the blower motor 10 Turn the ignition switch OFF 11 Disconnect the jumper wire 21 20 e 12 Disconnect heater contro panel connector 14 13 Check for continuity between the No 7 and No 8 terminals of heater control panel connector A 14P and body ground individually HEATER CONTROL PANEL CONNECTOR 14 Wire side of female terminals Is there continuity YES Repair any short to body ground in the wire s between the heater control panel and the power transistor NO Goto step 14 14 Check for continuity between the following terminals of heater control panel connector A 14P and power transistor 4P connector 14P 4P No 7 No 4 No 8 No 2 HEATER CONTROL PANEL CONNECTOR A 14P Wire side of female terminals POWER TRANSISTOR 4P CONNE
6. Heater Valve Cable Adjustment 1 From under the hood open the cable clamp 5 From under the hood turn the heater valve arm then disconnect the heater valve cable B from the to the fully closed position as shown and hold it heater valve arm C Attach the heater vaive cable B to the heater valve arm and gently pull on the heater valve cable housing to take up any slack then install the heater valve cable housing into the cable clamp A 2 From under the dash disconnect the heater valve cable housing from the cable clamp A and disconnect the heater valve cable B from the air mix control linkage 3 Set the temperature control dial on Max Cool with the ignition switch ON II 4 Attach the heater valve cable B to the air mix control linkage C as shown above then snap the heater valve cable housing into the cable clamp A 21 46 e Compressor Replacement Ifthe 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 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s preset buttons Disconnect the negative cable from the battery Recover the refrigerant with a recovery recycling charging station see page 21 53 Remove the alternator see page 4 29 Remove the A C condenser fan assembly see page 10 10 Dis
7. Is there battery voltage YES Update the ECM if it does not have the latest software or substitute a known good ECM then recheck see page 11 6 If the symptom indication goes away with a known good ECM replace the original NO Repair open in the wire between the compressor clutch relay and the ECM Il Disconnect the jumper wire Disconnect the compressor clutch 1P connector cont d 21 31 Heating and Air Conditioning Compressor Clutch Circuit A C Pressure Switch Circuit Troubleshooting cont d Troubleshooting 16 Check for continuity between the No 1 terminal of 1 Turn the ignition switch ON 11 the compressor clutch relay 4P socket and the No 1 terminal of the compressor clutch 1P connector 2 Turn the blower switch on and check for blower motor operation COMPRESSOR CLUTCH RELAY 4P SOCKET BLU RED Does the blower motor run on all speeds YES Go to step 3 Q NO Troubleshoot the blower motor circuit see page 21 20 3 Turn the ignition switch OFF BLU RED 4 Disconnect heater control panel connector 14 COMPRESSOR CLUTCH 1P CONNECTOR Terminal side of male terminals 5 Turn the ignition switch ON 11 Is there continuity 6 Measure the voltage between the No 4 terminal of heater control panel connector 14P and body YES Check the compressor clutch clearance the ground thermal protector and the compressor clutch field coil see page 21 48
8. M HEATER CONTROL PANEL CONNECTOR A 14 NO Repair open in the wire between the compressor clutch relay and the compressor clutch Wire side of female terminals Is there battery voltage YES Go to step 7 NO Go to step 9 7 Startthe engine 21 32 8 Connect the No 4 terminal of heater control 11 Check for continuity between the No 2 terminal of connector A 14P to body ground with a jumper the A C pressure switch 2P connector and the No 9 wire terminal of under dash fuse relay box connector 12 HEATER CONTROL PANEL CONNECTOR 14 A C PRESSURE SWITCH 2P CONNECTOR Wire side of female terminals BLU WHT 7 8 9 10 11 12 13 14 JUMPER WIRE 1 2 7 4 5 6 7 8 9110111 12 BLU WHT UNDER DASH FUSE RELAY BOX CONNECTOR F 12 Wire side of female terminals Wire side of female terminais Does the A C system come on Is there continuity YES Replace the heater control panel W YES Go to step 12 NO Refer to the multiplex control system see NO Repair open in the wire between the page 22 168 under dash fuse relay box and the A C pressure switch 9 Using the Backprobe Set connect the No 9 terminal of under dash fuse relay box connector 12 Check for continuity between the No 1 and No 2 F 12P to body ground with a jumper wire terminals of the A C pressure switch A C PRESSURE SWITCH UNDER DASH FUSE RELAY BOX CONNECTOR
9. of heater control panel connector 14 and body ground HEATER CONTROL PANEL CONNECTOR A 14P Wire side of female terminals Is there battery voltage YES Go to step 5 NO Repair open in the wire between the No 14 fuse in the under dash fuse relay box and the heater control panel 5 Turn the ignition switch OFF heater control panel connector A 14P and body ground HEATER CONTROL PANEL CONNECTOR A 14 5 3114 12 Wire side of female terminals 15 there continuity YES Check for loose wires or poor connections at heater control panel connector A 14P If the connections are good substitute a known good heater control panel and recheck If the symptom indication goes away replace the original heater control panel li NO Check for an open in the wire between the heater control panel and body ground If the wire is OK check for poor ground at G501 21 27 Heating and Air Conditioning Condenser Fan Circuit Troubleshooting NOTE If neither the condenser fan nor the radiator fan 4 Connect the No 1 and No 2 terminals of the work go to Radiator and Condenser Fans Common condenser fan relay 4P socket with a jumper wire Circuit Troubleshooting see page 21 29 CONDENSER FAN RELAY 4P SOCKET 1 Check the No 1 20 fuse in the under hood fuse relay box and the No 14 10A fuse in the under dash fuse relay box BLU YEL Are the
10. 15 relay OK fan relay the condenser fan relay and the YES Go to step 4 NO Replace the compressor clutch relay i 4 Measure the voltage between the No 2 terminal of the compressor clutch relay 4P socket and body ground COMPRESSOR CLUTCH RELAY 4P SOCKET Is there battery voltage YES Go to step 5 NO Replace the under hood fuse relay box 21 30 b 2 5 Connect No 1 and 2 terminals of the compressor clutch relay 4P socket with a jumper wire COMPRESSOR CLUTCH RELAY 4P SOCKET BLU RED JUMPER WIRE Does the compressor clutch click YES Go to step 6 NO Go to step 14 6 Disconnect the jumper wire 7 Turn the ignition switch ON II 8 Measure the voltage between the No 3 terminal of the compressor clutch relay 4P socket and body ground COMPRESSOR CLUTCH RELAY 4P SOCKET Is there battery voltage YES Go to step 9 NO Repair open in the wire between the No 14 fuse in the under dash fuse relay box and the compressor clutch relay lii 14 15 Turn the ignition switch OFF Reinstall the compressor clutch relay Make sure the A C switch is OFF Turn the ignition switch ON 11 Using the Backprobe Set measure the voltage between the No 18 terminal of ECM connector E 31P and body ground with the ECM connectors connected ECM CONNECTOR E 31P Wire side of female terminals
11. 15 there continuity YES Check for loose wires or poor connections at heater control panel connectors A 14 and B 22 and at the mode control motor 10P connector If the connections are good substitute a known good mode control motor and recheck If the symptom indication goes away replace the original mode control motor If the symptom indication continues substitute a known good heater control panel and recheck If the symptom indication goes away replace the original heater control panel I NO Repair any open in the wire s between the heater control panel and the mode control motor IN 21 19 Heating and Air Conditioning DTC Troubleshooting cont d DTC 12 A Problem in the Blower Motor 7 Check for continuity between the No 3 terminal of Circuit the power transistor 4P connector and body ground 1 Check the No 12 40A fuse in the under hood fuse relay box and the 14 10A fuse in the under dash fuse relay box POWER TRANSISTOR 4P CONNECTOR Are the fuses OK YES Go to step 2 NO Replace the fuse s and recheck I 2 Connect the No 2 terminal of the blower motor 2P connector to body ground with a jumper wire Wire side of female terminals BLOWER MOTOR 2P CONNECTOR MIN Is there continuity Ta YES Go to step 8 NO Check for an open in the wire between the power transistor and body ground If the wire is OK JUMPER BLU BLK check for poor ground at 6502
12. TEMPERATURE Is the resistance within the specifications shown on the graph YES Go to step 3 NO Replace the evaporator temperature sensor 3 Disconnect heater control panel connector 22 Check for continuity between the No 7 terminal of heater control panel connector 22 and the No 1 terminal of the evaporator temperature sensor 2P connector HEATER CONTROL PANEL CONNECTOR B 22P Wire side of female terminals 7 T EVAPORATOR TEMPERATURE SENSOR 2P CONNECTOR Wire side of female terminals Is there continuity YES Go to step 5 NO Repair open in the wire between the heater control panel and the evaporator temperature sensor W Disconnect heater control panel connector 14 21 23 Heating and Air Conditioning DTC Troubleshooting cont d 6 Check for continuity between the No 2 terminal of DTC 15 A Short in the Evaporator heater control panel connector A 14P and the Temperature Sensor Circuit No 2 terminal of the evaporator temperature sensor 2P connector 1 Remove the evaporator temperature sensor see page 21 37 HEATER CONTROL PANEL CONNECTOR A 14P Wire side of female terminals 2 Test the evaporator temperature sensor see page 21 37 15 the resistance within the specifications shown on the graph YES Go to step 3 NO Replace the evaporator temperature sensor W
13. F 12P 7 8 9 BLU WHT JUMPER WIRE R Wire side of female terminals 18 there continuity Does the A C system come on YES Repair open in the wire between the heater YES Go to step 10 control panel and the pressure switch I NO Refer to the multiplex control system see NO Go to step 13 page 22 168 8 13 Check for proper A C system pressure NOTE Check for multiplex codes in mode 1 Follow the troubleshooting for any codes found If no Is the pressure within specifications codes are found subsititute a known good multiplex control unit and a ECM one at a time YES Replace the A C pressure switch li 10 Disconnect the A C pressure switch 2P connector NO Repair the A C pressure problem i and under dash fuse relay box connector F 12P 21 33 Heating Air Conditioning Air Mix Contro Motor Test Air Mix Control Motor Replacement 4 1 Disconnect the 5 connector from the air mix 1 Remove the under dash fuse relay box see page control motor Connect battery power to the No 1 terminal of the air mix control motor and ground the No 2 terminal the air mix control motor should run and stop at Max Cool If it doesn t reverse the connections the air mix control motor should run and stop at Max Hot If the air mix control motor does not run remove it then check the air mix control linkage and door for
14. Qe 0 YELRED E LIGHT 10 RED RED BLK TAILUGHTS s RELAY RED BLK 12 UGHT GAUGE ASSEMBLY RED REAR 1 gt 42 HEATER CONTROL PANEL 1 2 BLU RED BLU YEL EVAPORATOR TEMPERATURE SENSOR LTGRN 1 2 5 GRY lt 5 3 PNK BLK Q AMD P AIR 1 CONTROL GRN 1 M COOL_ MOTOR 2 PNK BLU gt M HOT 2 YEL BLU YEL RED Pin DEF COM MODE RED YEL MODEI CONTROL RED BLU S due Moron 5 MODE3 S COM WHT BLU ED MODE3 YEL GRN MODE4 ________ LTGRN 2 GRN WHT O FRS RECIRCULATION 1 CONTROL 5 GRN YEL MOTOR 62 BLK CO CONNECTOR A 14 Z CONNECTOR B 22 LT GRN BLU WHT BLOWER MOTOR POWER TRANSISTOR BLK YEL BLK 6501 21 15 Heating and Air Conditioning DTC Troubleshooting DTC 7 An Open in the Air Mix Control Motor Circuit 1 Test the air mix control motor see page 21 34 Is the air mix control motor OK YES Go to step 2 NO Replace the air mix control motor 2 Disconnect the air mix control motor 5P connector 3 Disconnect heater control panel connectors A 14P and B 22P 4 Check for continuity between the following terminals of heater control panel connectors A 14P and B 22P and the air mix control motor 5P connector 14P 1 5 2 4 3 2
15. air mix control motor see page 21 34 Is the air mix control motor OK YES Substitute a known good heater control panel and recheck If the symptom indication goes away replace the original heater control panel W NO Replace the air mix control motor or repair the linkage and door iM 21 17 Heating and Air Conditioning DTC Troubleshooting DTC 10 An Open or Short in the Mode Control Motor Circuit 1 Test the mode control motor see page 21 35 Is the mode cotrol motor OK YES Go to step 2 Replace the mode control motor il 2 Disconnect the mode control motor 10P connector 3 Disconnect heater control panel connectors A 14P and B 22P 4 Check for continuity between body ground and heater control panel connector A 14P terminals 2 10 and 11 individually and between body ground and heater control panel connector B 22P terminals No 17 18 19 and 20 individually HEATER CONTROL PANEL CONNECTOR A 14P Wire side of female terminals HEATER CONTROL PANEL CONNECTOR B 22 3 41 6 1 jel 4 15 18 19 20 21 2 YEL GRN RED YEL WHT BLU RED BLU Wire side of female terminals Is there continuity YES Repair any short to body ground in the wire s between the heater control panel and the mode control motor liM Go to step 5 21 18 5 Turn the ignition switch ON Il and check the same t
16. items install the field coil with the wire side facing down and align the boss on the field coil with the hole in the compressor Clean the rotor pulley and compressor sliding surfaces with contact cleaner or other non petroleum solvent Install new snap rings note the installation direction and make sure they are fully seated in the groove Make sure that the rotor pulley turns smoothly after it s reassembled Route and clamp the wires properly or they can be damaged by the rotor pulley 21 50 Compressor Thermal Protector Compressor Relief Valve Replacement Replacement 1 Remove the bolt the ground terminal A and the 1 Recover the refrigerant with a recovery recycling holder B Disconnect the field coil connector C charging station see page 21 53 then remove the thermal protector D 2 Remove the relief valve A and the O ring B Plug the opening to keep foreign matter from entering the system and the compressor oil from running out 8 5 1 1 0 kgf m 7 2 suse 2 Replace the thermal protector A with new and apply silicone sealant to the bottom of the 3 Clean the mating surfaces thermal protector 4 Install a new O ring on the relief valve and apply a thin coat of refrigerant oil to the O ring 5 Remove the plug and install and tighten the relief valve 6 Charge the system see page 21 55 3 Install in the reverse order
17. of removal Heating and Air Conditioning Condenser Replacement 1 Recover the refrigerant with a recovery recycling charging station see page 21 53 2 Remove the front bumper see page 20 85 3 Remove the bolts then disconnect the discharge line A and the condenser line B from the condenser Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination 6x 1 0mm 9 8 1 0 kgf m 7 2 6x 1 0 mm 9 8 N m 1 0 kgf m 7 2 21 52 4 Remove the mounting bolts then remove the condenser by lifting it up Be careful not to damage the radiator or the condenser fins when removing the condenser 5 Install the condenser in the reverse order of removal and note these items If you re installing a new condenser add refrigerant oil KEIHIN SP 10 see page 21 6 Replace the O rings with new ones at each fitting and apply a thin coat of refrigerant oil before installing them Be sure to use the correct O rings for HFC 134a R 134a to avoid leakage Immediately after using the oil reinstall the cap on the container and seal it to avoid moisture absorption Do not spill the refrigerant oil on the vehicle it may damage the paint If the refrigerant oil contacts the paint wash it off immediately Be careful not to damage the radiator or the condenser fins when installing the condenser Charge the system see page 21 55 Lie Re
18. 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 refrigerant and polyalkyleneglycol PAG refrigerant 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 attempt 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 If 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 just before you reconnect each line Before connecting any hose or line apply a few drops of refrigerant oil to the O ring When tightening or loosening a fitting use a second wrenc
19. page 11 139 Enter the anti theft code for the radio then enter the customer s radio station presets 21 47 Heating and Air Conditioning Compressor Clutch Check 1 Check the armature plate for discoloration peeling 4 Release the field coil connector from the holder or other damage If there is damage replace the then disconnect it Check the thermal protector for clutch set see page 21 49 continuity If there is no continuity replace the thermal protector see page 21 51 2 Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand Replace the clutch set with a new one if it is noisy or has excessive play drag see page 21 49 NOTE The thermal protector will have no continuity above 252 to 270 F 122 to 132 C When the temperature drops below 241 to 219 F 116 to 104 C the thermal protector will have continuity 3 Measure the clearance between the rotor pulley A and the armature plate B all the way around If the clearance is not within specified limits remove the armature plate see page 21 49 and add or remove shims as needed to increase or decrease clearance Clearance 0 5 0 15 mm 0 020 0 006 in NOTE The shims are available in four thicknesses 0 1 mm 0 2 mm 0 4 mm and 0 5 mm 21 48 Check resistance of the field coil If resistance is not within specifications replace the field coil see page 21 49 Field Coil Resistance 3 05 3 35
20. smooth movement If the linkage and door move smoothly replace the air mix control motor If the linkage or door stick or bind repair them as needed If the air mix control motor runs smoothly go to step 3 AIR MIX CONTROL MOTOR Measure the resistance between the No 4 and No 5 terminals It should be between 2 1 k to 3 9kQ Reconnect the air mix control motor 5P connector then turn the ignition switch ON Il Using the Backprobe Set measure the voltage between the No 3 and No 4 terminals Max Cool about 1 V Max Hot about 4 V If either the resistance or voltage readings are not as specified replace the air mix cotrol motor 21 34 22 49 2 Disconnect the 5P connector A from the air mix control motor B Remove the self tapping screws and the air mix control motor from the heater unit Remove the rod C from the arm D of the air mix control motor 3 Install the motor in the reverse order of removal After installation make sure the motor runs smoothly e Mode Control Motor Test Mode Control Motor Replacement 1 Disconnect the 10P connector from the mode 1 Remove the ECM see page 11 4 control motor 2 Remove the relay mount bracket bolt and move 2 Connect battery power to the No 1 terminal of the the relays out of the way mode control motor and ground the No 2 terminal the mode control motor should run 3 Disconnect the 10P connector from
21. the mode smoothly and stop at Defrost If it doesn t reverse control motor B Remove the self tapping screws the connections the mode control motor should and the mode control motor from the heater unit run smoothly and stop at Vent When the mode control motor stops running disconnect battery power immediately MODE CONTROL MOTOR 112 4 5 6171819110 4 Install the motor the reverse order of removal Make sure the pin on the linkage is properly e engaged with the motor After installation make 3 If the mode control motor does not run in step 2 sure the motor runs smoothly remove it then check the mode control linkage and doors for smooth movement If the linkage and doors move smoothly replace the mode control motor If the linkage or doors stick or bind repair them as needed If the mode control motor runs smoothly go to step 4 4 Use a digital multimeter with an output of 1 mA or less at the 20 kQ range With the mode control motor running as in step 2 check for continuity between the No 4 5 6 7 8 and 9 terminals and the No 10 terminal individually There should be continuity for a moment at each terminal as the motor moves past each mode position 5 If there is no continuity for a moment at each terminal replace the mode control motor 21 35 Heating and Air Conditioning Recirculation Control Motor Test Recirculation Control Motor Replacement 1 Disconnect
22. 1 cont d 21 3 Heating and Air Conditioning Component Location Index cont d 4 RADIATOR RELAY Test page 22 51 COMPRESSOR CLUTCH RELAY Test page 22 51 BLOWER MOTOR RELAY Test page 22 51 UNDER HOOD FUSE RELAY BOX CONDENSER FAN RELAY Test page 22 51 A C PRESSURE SWITCH V ph RADIATOR FAN CONDENSER FAN wid 21 4 BLOWER UNIT HEATER UNIT CORE a and Installation page 21 39 Replacement page 21 43 BLOWER UNIT COMPONENTS P A page 21 41 HEATER VALVE CABLE Adjustment page 21 46 DUST AND POLLEN FILTER Replacement page 21 39 RECIRCULATION CONTROL MOTOR Test page 21 36 Replacement page 21 36 MODE CONTROL MOTOR Test page 21 35 Replacement page 21 35 POWER TRANSISTOR Test page 21 38 AIR MIX CONTROL MOTOR Test page 21 34 Replacement page 21 34 PUSH SWITCH ASSEMBLY EVAPORATOR TEMPERATURE Removal and Installation page 21 38 SENSOR Replacement page 21 37 Test page 21 37 HEATER CONTROL PANEL Removal and Installation page 21 38 21 5 Heating and Air Conditioning A C Service Tips and Precautions Compressed air mixed with R 134a forms a combustible vapor f 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
23. 9 1 22 6 3 HEATER CONTROL PANEL CONNECTOR 14 Wire side of female terminals AIR MIX CONTROL MOTOR PNK BLK 5P CONNECTOR Wire side of female terminals PNK BLK 3 4 5 ep pepe DD De o HEATER CONTROL PANEL CONNECTOR B 22 Wire side of female terminals 16 there continuity YES Check for loose wires or poor connections at heater control panel connectors A 14P and B 22P and at the air mix control motor connector If the connections are good substitute a known good air mix control motor and recheck If the symptom indication goes away replace the original air mix control motor If the symptom indication continues substitute a known good heater control panel and recheck If the symptom indication goes away replace the original heater contro panel NO Repair any open in the wire s between the heater control panel and the air mix control motor lI 21 16 DTC 8 A Short in the Air Mix Control Motor Circuit 1 Test the air mix control motor see page 21 34 Is the air mix control motor OK YES Go to step 2 NO Replace the air mix contoro motor M 2 Disconnect the air mix control motor 5P connector 3 Disconnect heater control panel connectors A 14P and B 22P 4 Check for continuity between body ground and heater control panel connector A 14P terminals 1 2 3 and 9 individually and bet
24. CTOR Wire side of female terminals Is there continuity YES Go to step 15 NO Repair any open in the wire s between the heater control panel and the power transistor 15 16 17 18 19 20 21 Reconnect heater control panel connector 14 Test the power transistor see page 21 38 Is the power transistor OK YES Check for loose wires or poor connections at heater control panel connector 14P and at the power transistor 4P connector If the connections are good substitute a known good heater control panel and recheck If the symptom indication goes away replace the original heater control panel li NO Replace the power transistor lil Disconnect the jumper wire Disconnect the blower motor 2P connector Measure the voltage between the No 1 terminal of the blower motor 2P connector and body ground BLOWER MOTOR 2P CONNECTOR BLU WHT Wire side of female terminals Is there battery voltage YES Replace the blower motor IN Go to step 20 Turn the ignition switch OFF Remove the blower motor relay from the under hood fuse relay box and test it see page 22 51 Is the relay OK YES Go to step 22 NO Replace the blower motor relay cont d 21 21 Heating and Air Conditioning DTC Troubleshooting cont d 22 Measure the voltage between the No 3 terminal of the blower motor relay 4P socket and body ground BLOWER MOTOR RE
25. LAY 4P SOCKET Is there battery voltage YES to step 23 NO Replace the under hood fuse relay box lil 23 Turn the ignition switch ON II 24 Measure the voltage between the No 2 terminal of the blower motor relay 4P socket and body ground BLOWER MOTOR RELAY 4P SOCKET BLK YEL Is there battery voltage YES Go to step 25 NO Repair open in the wire between the No 14 fuse in the under dash fuse relay box and the blower motor relay 21 22 25 Turn the ignition switch OFF 26 Check for continuity between the No 1 terminal of the blower motor relay 4P socket and body ground BLOWER MOTOR RELAY 4P SOCKET 15 there continuity YES Repair open in the BLU WHT wire between the blower motor relay and the blower motor li NO Check for an open in the wire between the blower motor relay and body ground If the wire is OK check for poor ground at G301 14 e e DTC 14 An Open in the Evaporator Temperature Sensor Circuit 1 Remove the evaporator temperature sensor see page 21 37 2 Measure the resistance between the No 1 and No 2 terminals of the evaporator temperature sensor Dip the sensor in ice water and measure resistance Then pour hot water on the sensor and check for change in resistance EVAPORATOR TEMPERATURE SENSOR Terminal side of male terminals 40 RESISTANCE 20 pee 10 32 50 68 86 F 0 10 20 30 C
26. ME 1 GRY AIR MIX POTENTIAL 5V OUTPUT 2 LT GRN SENSOR COMMON GROUND INPUT 3 PNK BLU AIR MIX HOT OUTPUT 4 BLU A C PRESSURE SWITCH INPUT 5 GRN YEL RECIRCULATE P INPUT 6 GRN WHT FRESH m INPUT d 4 BLU YEL POWER TRANSISTOR OUTPUT 8 BLU RED BLOWER FEEDBACK gt INPUT 9 GRN AIR COOL OUTPUT 10 YEL RED _ MODE DEF OUTPUT 11 YEL BLU__ MODE VENT _ OUTPUT _ 12 YEL BLK REAR WINDOW DEFOGGER RELAY INPUT 13 BLK GROUND 3 OUTPUT 14 BLK YEL 162 Power INPUT CONNECTOR B _ on Circuit Diagram Cavity Wire color Signal 1 UR T 2 ae 3 BLK RED REAR WINDOW DEFOGGER SWITCH LED INPUT 4 LT GRN AICSWITCHLED _ _ 5 LT GRN BLK RECIRCULATION CONTROL SWITCH LED INPUT 6 i PNK BLK AIR MIX POTENTIAL OUTPUT J BRN EVAPORATOR TEMPERATURE SENSOR OUTPUT 8 iem RECEN 9 Ae i an 2270 rd ER __ 11 RED GAUGE ASSEMBLY _____ OUTPU 12 RED BLK TAILLIGHTS RELAY INPUT 13 PIE 14 BLU REAR WINDOW DEFOGGER SWITCH INPUT 15 LT GRN RED SWITCH INPUT 16 E YEL RED RECIRCULATION CONTROL SWITCH INPUT 17 YEL GRN 4 OUTPUT 18 WHT BLU MODE 3 _ OUTPUT 19 RED BLU MODE 2 OUTPUT _ 20 RED YEL MODE 1 _ ___ __ 21 BRN WHT IGN Power OUTPUT 22 RED WHT Not used cont d 21 11 Heating and Air Conditioning System Description cont d The air conditioning system removes heat from the passenger compartment by circulating refriger
27. OWER TRANSISTOR 3 Carefully release the lock tab on the No 4 terminal BLU YEL A in the 4P connector then remove the terminal and insulate it from body ground To 12 V power source on vehicle 4 Reconnect the 4P connector to the power transistor 5 Supply 12 volts to the No 4 cavity with a jumper wire 6 Turn the ignition switch ON II and check that the blower motor runs If the blower motor does not run replace the power transistor If the blower motor runs the power transistor is OK 21 38 Heater Control Panel and Push Switch Assembly Removal and Installation 1 Remove the center panel see page 20 62 2 Remove the dials A then remove the self tapping screws and the heater control panel B from the center panel C Remove the self tapping screws and the push switch assembly D from the center panel 3 Install the control panel and push switch assembly in the reverse order of removal After installation operate the control panel controls to see whether it works properly 4 Run the self diagnosis function to confirm that there are no problems in the system see page 21 8 Dust and Pollen Filter Replacement Blower Unit Removal and Installation The dust and pollen filters should be replaced every 30 000 miles 48 000 km or 24 months whichever comes first Replace the filters more often if the air flow For some models SRS componen
28. Temperature Sensor Evaporator Temperature Sensor Replacement Test 1 Remove the driver s dashboard lower cover see 1 Dip the sensor in ice water and measure the page 20 59 and the under cover see page 20 60 resistance between its terminals 2 Remove the under dash fuse relay box see page EVAPORATOR TEMPERATURE SENSOR 22 49 3 Disconnect the 2P connector A from the D evaporator temperature sensor B then remove 1 12 the connector clip Remove the self tapping screw and carefully pull out the evaporator temperature Terminal side of male terminals 2 Then pour hot water on the sensor and check for a change in resistance 3 Compare the resistance readings with the specifications shown in the graph the resistance should be within the specifications 40 4 Install the sensor the reverse order of removal 30 k RESISTANCE kQ 20 i 32 50 68 86 F 0 10 20 30 TEMPERATURE 14 21 37 Heating and Air Conditioning Power Transistor Test 1 Disconnect the 4P connector from the power transistor 2 Measure the resistance between the No 1 and 2 terminals of the power transistor It should be about 1 4 1 5 f the resistance is within the specifications go to step 3 If the resistance is not within the specifications replace the power transistor P
29. an relay and the condenser fan 11 Check for continuity between the No 1 terminal of the condenser fan 2P connector and body ground CONDENSER FAN 2P CONNECTOR Wire side of female terminals Is there continuity YES Replace the condenser fan motor W Check for an open in the wire between the condenser fan and body ground If the wire is OK check for poor ground G301 m t 5 Radiator and Condenser Fans Common Circuit Troubleshooting NOTE If both fans and the A C compressor clutch do not work when the A C switch is on go to A C Pressure Switch Circuit Troubleshooting see page 21 32 1 Check the No 1 20A and No 4 20 fuses in the under hood fuse relay box and the No 14 10A fuse in the under dash fuse relay box Are the fuses OK YES Go to step 2 NO Replace the fuse s and recheck 2 Remove the condenser fan relay from the under hood fuse relay box 3 Turn the ignition switch ON II 4 Measure the voltage between the No 3 terminal of the condenser fan relay 4P socket and body ground CONDENSER FAN RELAY 4P SOCKET Is there battery voltage YES Go to step 5 NO Repair open in the wire between the No 14 fuse in the under dash fuse relay box and the radiator fan relay and the condenser fan relay W 5 Turn the ignition switch OFF 6 Reinstall the condenser fan relay 7 Make sure the A C switch is OFF 8 Turn the ignition switch ON ID
30. ant through the system as shown below BLOWER FAN NALS Absorption of heat EVAPORATOR TEMPERATURE EXPANSION VALVE Meters the required amount of refrigerant into the evaporator SENSOR A C PRESSURE SWITCH THERMAL PROTECTOR When the refrigerant is below Opens the compressor clutch circuit 196 kPa 2 0 kgf cm 28 psi when the compressor temperature or above 3 140 kPa 32 kgf cm becomes too high 455 psi the A C pressure switch opens the circuit to RELIEF VALVE the A C switch and stops the Relieves pressure at the compressor air conditioning to protect the A when the pressure is too high compressor A C COMPRESSOR RECEIVER DRYER Suction and compression Traps debris and removes moisture PRESSURE VAPOR HIGH PRESSURE LIQUID 77 Low PRESSURE LIQUID LOW PRESSURE VAPOR CONDENSER Radiation of heat This vehicle uses HFC 134a R 134a refrigerant which does not contain chlorofiuorocarbons Pay attention to the following service items Do not mix refrigerants CFC 12 R 12 and HFC 134a R 134a They are not compatible Use only the recommended polyalkyleneglycol PAG refrigerant oil KEIHIN SP 10 designed for the R 134a compressor Intermixing the recommended refrigerant with any other refrigerant oil will result in compressor failure All A C system parts compressor discharge line suction line evaporator condenser receiver
31. b e HVAC Heating Ventilation and Air Conditioning Heating and Air conditioning Special Tools 21 2 Component Location Index 21 3 Service Tips and Precautions 21 6 Refrigerant Oil Replacement 21 6 General Troubleshooting Information 2 2022 2 2 21 8 DTC Troubleshooting Index 21 9 Symptom Troubleshooting RE System Description Circuit Diagram DTC Troubleshooting 21 16 Recirculation Control Motor Circuit Troubleshooting 21 25 Heater Control Power and Ground Circuits Troubleshooting 21 27 Condenser Fan Circuit Troubleshooting 21 28 Radiator and Condenser Fans Common Circuit Troubleshooting 21 29 Compressor Clutch Circuit Troubleshooting 2222222 21 30 Pressure Switch Circuit Troubleshooting 21 32 Air Mix Control Motor Test and Replacement 21 34 Mode Control Motor Test and Replacement 21 35 Recirculation Control Motor Test and Replacement 21 36 Evaporator Temperature Sensor Replacement and Test 21 37 Power Transistor Test 21 38 Heater Control Panel and Push Switch Assembly Removal and Installation 21 38 Dust and Pollen Filter Replacement
32. ccurs ventilate the work area before resuming service Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 When an A C system has been opened to the atmosphere such as during installation or repair it must be evacuated using a R 134a refrigerant recovery recycling charging station If the system has been open for several days the receiver dryer should be replaced and the system should be evacuated for several hours 21 54 Connect R 134a refrigerant recovery recycling charging station A to the high pressure service port B and the low pressure service port C as shown following the equipment manufacturer s instructions Evacuate the system If the low pressure does not reach more than 93 3 kPa 700 mmHg 27 6 in Hg in 15 minutes there is probably a leak in the system Partially charge the system and check for leaks see step 3 on page 21 56 e 4 System Charging CAUTION ______ Air conditioning refrigerant or lubricant vapor can irritate your eyes nose or throat Becareful when connecting service equipment Do not breathe refrigerant or vapor Use only service equipment that is U L listed and is certified to meet the requirements of SAE J2210 to remove HFC 134a R 134a from the air conditioning system If accidental system discharge occurs ventilate the work area before resuming service Additional healt
33. connect the compressor clutch connector remove the bolts then disconnect the suction line B and the discharge line C from the compressor Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination 8 Remove the mounting bolts and the compressor 8x 1 25 mm 22 2 2 kgf m 16 Ibf ft Install the compressor in the reverse order of removal and note these items Before installing the new compressor check for metal or other contamination in the line Replace any contaminated parts If you re installing a new compressor you must calculate the amount of refrigerant oil to be removed from it see page 21 6 Replace the O rings with new ones at each fitting and apply a thin coat of refrigerant oil before installing them Be sure to use the correct O rings for HFC 134a R 134a to avoid leakage Use refrigerant oil KEIHIN SP 10 for HFC 134a KEIHIN spiral type compressor only To avoid contamination do not return the oil to the container once dispensed and never mix it with other refrigerant oils Immediately after using the oil reinstall the cap on the container and seal it to avoid moisture absorption Do not spill the refrigerant oil on the vehicle it may damage the paint If the refrigerant oil contacts the paint wash it off immediately Charge the system see page 21 55 Do the engine control module ECM idle learn procedure see
34. cycling 5 Carefully pull out the evaporator core without charging station see page 21 53 bending the pipes 2 Remove the bolt then disconnect the suction line A and the receiver line B from the evaporator core 6 install the core in the reverse order of removal and note these items 98 8 N m T 1 0 kgfm 7 2 If you re installing a new evaporator core add 3 Remove the blower unit see page 21 39 refrigerant oil KEIHIN SP 10 see page 21 6 Replace the O rings with new ones at each fitting 4 Remove the self tapping screws and the expansion and apply a thin coat of refrigerant oil before valve cover installing them Be sure to use the correct O rings for HFC 134a R 134a to avoid leakage Immediately after using the oil reinstall the cap on the container and seal it to avoid moisture absorption Do not spill the refrigerant oil on the vehicle it may damage the paint If the refrigerant oil contacts the paint wash it off immediately Charge the system see page 21 55 21 42 e Heater Unit Core Replacement SRS components are located in this area Review the SRS component locations see page 23 13 and precautions and procedures see page 23 14 in the SRS section before performing repairs or service 1 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s preset buttons 2 Disconnect the negative cable from the batter
35. d receiver dryer Clogged high pressure line Repair or replace Refrigerant leaks Compressor clutch is dirty Compressor shaft seal leaking Replace the compressor Compressor bolt s are dirty Leaking around bolt s Tighten 5 or replace compressor Compressor gasket is wet with oil Gasket leaking Replace the compressor cont d 21 57 Heating and Air Conditioning A C System Tests cont d Performance Test 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 AUTION Air conditioning refrigerant or lubricant vapor can irritate your eyes nose or throat Becareful when connecting service equipment Do not breathe refrigerant or vapor The performance test will help determine if the air conditioner system is operating within specifications Use only service equipment that is U L listed and is certified to meet the requirements of SAE J2210 to remove HFC 134a 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 b
36. d the bracket D t 12 Remove the self tapping screws and the expansion valve cover A Carefully pull out the evaporator core B so you don t bend the inlet and outlet pipes Remove the grommet C then remove the self tapping screws and the flange cover D Remove 10 Disconnect the connectors from the evaporator the self tapping screws and the pipe cover E then 4 temperature sensor and the air mix control motor carefully pull out the heater core F so you don t then remove the wire harness clips B and the bend the inlet and outlet pipes connector Remove the self tapping screw and the cover 0 Disconnect the heater valve cable 21 44 Lio Install the heater core and the evaporator core in the reverse order of removal Install the heater unit in the reverse order of removal and note these items Do not interchange the inlet and outlet heater hoses and install the hose clamps securely Refill the cooling system with engine coolant see page 10 6 Adjust the heater valve cable see page 21 46 Make sure that there is no coolant leakage Make sure that there is no air leakage Refer to evaporator core replacement see step 6 on page 21 42 Do the engine control module ECM idle learn procedure see page 11 139 Enter the anti theft code for the radio then enter the customer s radio station presets 21 45 Heating Air Conditioning
37. does not run at all but Condenser Fan Circuit Poor ground at G301 radiator fan runs with the A C on Troubleshooting see page 21 28 Cleanliness and tightness of all _ connectors 2 Both fans do not run with the A C on Radiator and Condenser Fans Blown fuse No 1 20A and No 4 Common Circuit Troubleshooting 20 in the under hood fuse relay see page 21 29 Poor ground at 6301 Cleanliness and tightness of all connectors Compressor clutch does not engage Compressor Clutch Circuit Cleanliness and tightness of all both fans run with Troubleshooting see page 21 30 connectors A C system does not come on both A C Pressure Switch Circuit Blown fuse No 1 20A and No 4 fans and compressor Troubleshooting see page 21 32 20A in the under hood fuse relay box Poor ground at G301 Cleanliness and tightness of all connectors 21 10 e System Description Heater Control Panel Inputs and Outputs CONNECTOR A 14 HEATER CONTROL PANEL CONNECTORS CONNECTOR B 22 BE 7 8 9 1 Tr 6 314151 4 a fis is BT CONNECTOR lt on Circuit Diagram Wire side of female terminals Cavity Wirecolor _ _ Signal P
38. dryer expansion valve O rings for joints have to be designed for refrigerant R 134a Do not exchange with R 12 parts Use a halogen gas leak detector designed for refrigerant R 134a R 12 and R 134a refrigerant servicing equipment are not interchangeable Use only a recovery recycling charging station that is U L listed and is certified to meet the requirements of SAE J2210 to service R 134a air conditioning system Always recover the refrigerant R 134a with an approved recovery recycling charging station before disconnecting any fitting 21 12 Heating and Air Conditioning Circuit Diagram IGNITION SWITCH UNDER DASH UNDER HOOD FUSE RELAY BOX G2 HOT in ON Ili FUSE RELAY BOX No 19 80A No 20 40A ING BLK RED BLK YEL RADIATOR CONDENSER COMPRESSOR BLOWER UM FAN FAN 4 CLUTCH ed MOTOR RELAY RELAY _ RELAY RELAY 1 4 BLU BLK GRNIWHT BLU YEL RED BLU WHT THERMAL PROTECTOR COMPRESSOR CLUTCH MULTIPLEX EE AIC PRESSURE t2 VEL i abs SLU WHT Hc GRN WHT RADIATOR RADIATOR PON DENGER MOTOR MOTOR 1 fene Above 1 Meere BLK In the under dash fuse relay box Git 6301 21 14 BLK YEL BLU WHT PUSH SWITCH ASSEMBLY Uu BRN WHT new BLK RED LTGRN BLK 5 OA M si LTGRN REO 6
39. e obtained from the refrigerant and lubricant manufacturers 1 Connect a R 134a refrigerant recover recycling charging station to the high pressure service port and the low pressure service port following the equipment manufacturer s instructions 2 Determine the relative humidity and air temperature 21 58 3 Open the glove box Remove both glove box stops then let the glove box hang down see page 20 63 4 insert a thermometer A in the center vent and place another thermometer B near the blower unit 5 Test conditions Avoid direct sunlight Open the hood Open the front doors Setthe temperature control dial on Max Cool the mode control dial on Vent and the recirculation control switch on Recirculate Turn the A C switch on and the fan switch on Max Run the engine at 750 rpm No driver or passengers in vehicle 6 After running the air conditioning for 10 minutes under the above test conditions read the delivery temperature from the thermometer in the center vent the intake temperature near the blower unit and the high and low system pressure from the A C gauges 4 Ld To complete the charts Markthe delivery temperature along the vertical line Mark the intake temperature ambient air temperature along the bottom line Draw a line straight up from the air temperature to the humidity Mark a point 10 above and 10 below the humidity leve
40. e refrigerant or vapor Use only service equipment that is U L listed and is certiified to meet the requirements of SAE J2210 to remove HFC 134a R 134a from the air conditioning system If 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 21 56 Connect a R 134a refrigerant recovery recycling charging station A to the high pressure service port and the low pressure service port shown following the equipment manufacturer s instructions Open the high pressure valve to charge the system to the specified capacity then close the supply valve and remove the charging system couplers Select the appropriate units of measure for your refrigerant charging station Refrigerant capacity 500 to 550 g 0 50 to 0 55 kg 1 10 to 1 21 Ibs 17 6 to 19 4 oz Check the system for leaks using a R 134a refrigerant leak detector with an accuracy of 14 g 0 5 oz per year or better If you find leaks that require the system to be opened to repair or replace hoses fittings etc recover the system After checking and repairing leaks evacuate the system A C System Tests Pressure Test Te
41. erminals for voltage HEATER CONTROL PANEL CONNECTOR A 14 Wire side of female terminals HEATER CONTROL PANEL CONNECTOR B 22P Wire side of female terminals Is there any voltage YES Repair any short to power in the wire s between the heater control panel and the mode control motor This short may also damage the heater control panel Repair the short to power before replacing the heater contro panel I NO Go to step 6 4 6 the ignition switch OFF and check for DTC 11 A Problem in the Mode Control continuity between the following terminals of Linkage Doors or Motor heater control panel connectors A 14 and 22P and the mode control motor 10P connector 1 Test the mode control motor see page 21 35 14P 10P No 2 No 10 15 the mode control motor OK No 10 No 1 No 11 No 2 YES Substitute a known good heater control panel and recheck If the symptom indication goes 22P 10P away replace the original heater contro panel No 17 8 No 18 No 6 9 NO Replace the mode contro motor or repair the No 19 No 5 linkage and doors No 20 No 4 7 HEATER CONTROL PANEL CONNECTOR A 14P Wire side of female terminals MODE CONTROL MOTOR 10P CONNECTOR Wire side of female terminals 17 18 19 20 21 22 YEL GRN RED YEL WHT BLU RED BLU HEATER CONTROL PANEL CONNECTOR B 22P Wire side of female terminals
42. frigerant Recovery Air conditioning refrigerant or lubricant vapor can irritate your eyes nose or throat Becareful when connecting service equipment Do not breathe refrigerant or vapor Use only service equipment that is U L listed and is certified to meet the requirements of SAE J2210 to remove HFC 134a R 134a from the air conditioning system If accidental system discharge occurs ventilate the work area before resuming service Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 Connect a R 134a refrigerant recovery recycling charging station to the high pressure service port B and the low pressure service port C as shown following the equipment manufacturer s instructions 2 Measure the amount of refrigerant oil removed from the A C system after the recovery process is completed Be sure to put the same amount of new refrigerant oil back into the A C system before charging 21 53 Heating and Air Conditioning System Evacuation 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 Use only service equipment that is U L listed and is certified to meet the requirements of SAE J2210 to remove HFC 134a R 134a from the air conditioning system If accidental system discharge o
43. fuses OK JUMPER WIRE YES Go to step 2 NO Replace the fuse s and recheck lil 2 Remove the condenser fan relay from the under hood fuse relay box and test it see page 22 51 Does the condenser fan run Is the relay OK YES Go to step 5 YES Go to step 3 NO Go to step 8 NO Replace the condenser fan relay I 5 Disconnect the jumper wire 3 Measure the voltage between the No 2 terminal of the condenser fan relay 4P socket and body ground 6 Turn the ignition switch ON 1 CONDENSER FAN RELAY 4P SOCKET 7 Measure the voltage between the No 3 terminal of the condenser fan relay 4P socket and body ground CONDENSER FAN RELAY 4P SOCKET Is there battery voltage YES Go to step 4 Is there battery voltage NO Replace the under hood fuse relay box i YES Replace the under hood fuse relay box IM NO Repair open in the wire between the No 14 fuse in the under dash fuse relay box and the condenser fan relay 8 Disconnect the jumper wire 21 28 9 Disconnect the condenser fan 2P connector 10 Check for continuity between the No 1 terminal of the condenser fan relay 4P socket and the No 2 terminal of the condenser fan 2P connector CONDENSER FAN RELAY 4P SOCKET BLU YEL CDi CONDENSER FAN 2P CONNECTOR Wire side of female terminals Is there continuity YES Go to step 11 NO Repair open in the wire between the condenser f
44. h and safety information may be obtained from the refrigerant and lubricant manufacturers 1 Connect a R 134a refrigerant recovery recycling charging station A to the high pressure service port B and the low pressure service port C as shown following the equipment manufacturer s instructions 2 Evacuate the system see page 21 54 3 Add the same amount of new refrigerant oil to the system that was removed during recovery Use only KEIHIN SP 10 refrigerant oil Charge the system with the specified amount of R 134a refrigerant Do not overcharge the system the compressor will be damaged Select the appropriate units of measure for your refrigerant charging station Refrigerant capacity 500 to 550 0 50 to 0 55 kg 1 10 to 1 21 Ibs 17 6 to 19 4 oz Check for refrigerant leaks see page 21 56 Check for system performance see page 21 58 21 55 Heating and Air Conditioning Refrigerant Leak Test Special Tool Required Leak detector Honda Tool and Equipment YGK H 10PM commercially available 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 system Air conditioning refrigerant or lubricant vapor can irritate your eyes nose or throat Becareful when connecting service equipment Do not breath
45. h to support the matching fitting When discharging the system use a R 134a refrigerant recovery recycling charging station don t release refrigerant into the atmosphere 21 6 A C Refrigerant Oil Replacement Recommended PAG oil KEIHIN SP 10 P N 38897 13 120 4 fl oz P N 38899 P13 A01 40 m2 1 1 3 1 02 Add the recommended refrigerant oil in the amount listed if you replace any of the following parts To avoid contamination do not return the oil to the container once dispensed and never mix it with other refrigerant oils Immediately after using the oil reinstall the cap on the container and seal it to avoid moisture absorption Do not spill the refrigerant oil on the vehicle it may damage the paint If it gets on the paint wash it off immediately Condenser 25 m2 5 6 fl oz 0 9 Imp oz Evaporator 45 m2 1 1 3 fl oz 1 4 Imp oz Line or hose 10 m 1 3 fl oz 0 4 Imp oz Receiver Dryer 10 m2 1 3 fl oz 0 4 Imp oz Leakage repair 25 m8 5 6 fl oz 0 9 Imp oz Compressor For compressor replacement subtract the volume of oil drained from the removed compressor from 130 m 4 1 3 fl oz 4 6 Imp oz and drain the calculated volume of oil from the new compressor 130 m2 4 1 3 fl oz 4 6 Imp oz Volume of removed compressor Volume to drain from new compressor NOTE Even if no is drained from the removed compressor don t drain more t
46. han 50 1 2 3 fl oz 1 8 Imp oz from the new compressor REMOVED NEW COMPRESSOR COMPRESSOR jim SAME LEVEL 130 m2 4 1 3 fl oz 4 6 Imp oz ec DRAINING VOLUME 7 A 4 RECEIVER LINE HEATER UNIT SUCTION LINE RECEIVER DRYER CONDENSER LINE CONDENSER COMPRESSOR BRACKET Discharge hose to the compressor 6 x 1 0 mm 9 8 1 0 kgf m 7 2 Ibf ft Discharge hose to the condenser 6 x 1 0 9 8 N m 1 0 kgf m 7 2 Ibf ft ondenser line to the condenser 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft ondenser line to the receiver dryer 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft Receiver line A to the receiver dryer 6 x 1 0 mm 9 8 1 0 kgf m 7 2 Ibf ft gt Receiver line to the receiver line 13 N m 1 3 kgf m 9 4 Ibf ft Receiver line and the suction line to the evaporator 6 x 1 0 mm 9 8 1 0 kgf m 7 2 Ibf ft 2 Suction line to the suction hose 31 N m 3 2 kgf m 23 156 j Suction hose to the compressor 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 49 Compressor to the compressor bracket 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft 2 Compressor bracket to the engine block 10 x 1 25 44 N m 4 5 kgf m 33 Ibf ft 21 7 Heating and Air Conditioning General Troubleshooting Information How to Retrieve a DTC The heater contro panel has a self diagnosis function To run the self diagno
47. l From each point draw a horizontal line across the delivery temperature The delivery temperature should fall between the two lines Complete the low side pressure test and high side pressure test in the same way Any measurements outside the line may indicate the need for further inspection kPa kPa psi psi 2500 600 25 6 360 85 80 80 2000 500 HUMIDITY 20 5 71 LEVEL F C 30 m mW 1 210 57 30 DELIVERY PRESSURE sum 1000 300 74 10 3 25 11401 431 HUMIDITY LEVEL 500 200 4 68 5 2 20 71 28 DELIVERY PRESSURE INTAKE 100 59 PRESSURE 1 15 14 PRESSURE 50 4 10 DELIVERY 4 4 TEMPERATURE 5 DELIVERY TEMPERATURE i 68 77 86 95 104 F 20 25 30 35 4 INTAKE TEMPERATURE 21 59
48. lays and bracket assembly then remove the ECM bracket 11 9 Disconnect the connectors A from the blower motor and the power transistor then remove the 12 wire harness clips B and the connectors C Remove the self tapping screws and the bracket D 13 A 14 21 40 10 Disconnect the connector from the recirculation control motor then remove the wire harness clip B Remove the mounting bolts the mounting nuts and the blower unit C 1 0 mm 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 6x 1 9 8 N m 1 0 kgf m 7 2 Ibf ft Install the unit in the reverse order of removal Make sure that there is no air leakage Reconnect the negative battery terminal Dothe engine control module ECM idle learn procedure see page 11 139 Enter the anti theft code for the radio then enter the customer s radio station presets Blower Unit Components Replacement Note these items when overhauling the blower unit The recirculation control motor the power transistor B the blower motor C and the dust and pollen filters D can be replaced without removing the blower unit Before reassembly make sure that the recirculation control linkage and doors move smoothly After reassembly make sure the recirculation control motor runs smoothly see page 21 36 21 41 Heating and Air Conditioning Evaporator Core Replacement 1 Recover the refrigerant with a recovery re
49. nel connector A 14P NO Go to step 10 cont di 21 25 Heating and Air Conditioning Recirculation Control Motor Circuit Troubleshooting cont d 4 10 Turn the ignition switch OFF 11 Check for continuity between the following terminals of heater control panel connector and the recirculation control motor 5P connector 5 1 No 6 No 2 HEATER CONTROL PANEL CONNECTOR A 14 Wire side of female terminals GRN YEL GRN WHT RECIRCULATION CONTROL MOTOR 5P CONNECTOR Wire side of female terminals Is there continuity YES Check for loose wires or poor connections at heater control panel connector A 14P and at the recirculation control motor 5P connector If the connections are good substitute a known good heater control panel and recheck If the symptom indication goes away replace the original heater control panel NO Repair any open in the wire s between the heater control panel and the recirculation control motor 21 26 Heater Control Power and Ground Circuits Troubleshooting 1 Check the No 14 10A fuse in the under dash 6 Check for continuity between the No 13 terminal of fuse relay box Is the fuse OK YES Go to step 2 NO Replace the fuse and recheck IM 2 Disconnect heater control panel connector A 14P 3 Turn the ignition switch ON 1 4 Measure the voltage between the No 14 terminal
50. ohms at 68 F 20 C Compressor Clutch Overhaul Special Tool Required clutch holder Robinair 10204 Kent Moore J37872 or Honda and Equipment KMT J33939 commercially available 1 Remove the center nut A while holding the armature plate with a commercially available A C clutch holder B A 17 6 1 8 kgf m 13 2 Remove the armature plate and shimis taking care not to lose the shim s If the clutch needs adjustment increase or decrease the number and thickness of shims as necessary then reinstall the armature plate and recheck its clearance see page 21 48 NOTE The shims are available in four thicknesses 0 1 mm 0 2 mm 0 4 mm and 0 5 mm 3 If you are replacing the field coil remove the snap ring with snap ring pliers then remove the rotor pulley Be careful not to damage the rotor pulley or the compressor 4 Remove the bolt and holder A then disconnect the field coil connector B Loosen the clamp screw C to free the field coil wire Remove the snap ring D with snap ring pliers then remove the field coil E Be careful not to damage the field coil or the compressor DN E 7 4 Rs 0 75 kgf m 5 Ibf ft cont d 21 49 Heating and Air Conditioning Compressor Clutch Overhaul cont d 5 Reassemble the clutch in the reverse order of disassembly and note these
51. ontrol motor circuit see page 21 16 8 A short in the air mix control motor circuit see page 21 16 9 problem in the air mix control linkage door or motor see page 21 17 10 An open or short in the mode control motor circuit see page 21 18 11 A problem in the mode contro linkage doors or motor see page 21 19 12 A problem in the blower motor circuit see page 21 20 13 A problem in the EEPROM in the heater control panel see page 21 38 the control panel must be replaced 14 An open in the evaporator temperature sensor circuit see page 21 23 15 A short in the evaporator temperature sensor circuit see page 21 24 In case of multiple problems the recirculation indicator will indicate only the DTC with the least number of blinks Incase of an intermittent failure the heater control panel will store the DTC until the ignition is turned off 21 9 Heating and Air Conditioning Symptom Troubleshooting Index Symptom Diagnostic procedure Also check for Recirculation control doors do not Recirculation Control Motor Cleanliness and tightness of all change between Fresh and Recirculate Circuit Troubleshooting see page connectors 21 25 Both heater and A C do not work i Heater Control Power and Ground Blown fuse 14 10A in the Circuits Troubleshooting see under dash fuse relay box page 21 27 Poor ground at G501 Cleanliness and tightness of all connectors em Condenser fan
52. ow and the air flow from vents is restricted Frozen evaporator Run the fan with compressor off then check evaporator temperature sensor Expansion valve is frosted Clogged expansion valve Clean or replace Receiver dryer outlet is cool and inlet is warm should be warm during operation Clogged receiver dryer Replace receiver dryer Suction pressure abnormally high Low pressure hose and check joint are cooler than the temperature around evaporator Expansion valve open too long Repair or replace i Suction pressure is lowered when condenser is cooled by water Excessive refrigerant in system Recover evacuate and recharge with specified amount High and low pressure are equalized as soon as the compressor is stopped and both gauges fluctuate while running Faulty gasket Faulty high pressure valve Foreign particle stuck in high ressure valve Replace the compressor discharge pressure abnormally low areas are cooler than evaporator hose parts Suction and Reduced air flow through condenser Clogged condenser or radiator Clean discharge fins Check voltage and fan rpm pressures Condenser or radiator fan not Check fan direction abnormelly high working properly Suction and Low pressure hose and metal end Clogged or kinked low pressure Repair or replace Temperature around expansion valve is too low compared with that aroun
53. sis function do the following 1 Turn the fan switch OFF 2 Press and hold the recirculation control switch and the rear window defogger switch down 3 Turn the ignition switch ON II 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 A 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 If any trouble is found the recirculation indicator blinks the diagnostic trouble code DTC to indicate a faulty circuit or component If the system is OK the recirculation indicator stays off A C INDICATOR FAN SWITCH RECIRCULATION REAR WINDOW SAT DEFOGGER INDICATOR RECIRCULATION WINDOW CONTROL SWITCH DEFOGGER SWITCH Example of DTC indication Pattern DTC 7 0 3 sec DTC Recirculation indicator comes on Recirculation indicator te goes off oc 4 H 3sec i 03sec 15sec Resetting the Self diagnosis Function Turn the ignition switch OFF to cancel the self diagnosis function After completing repair work run the self diagnosis function again to make sure that there are no other malfunctions 21 8 e DTC Troubleshooting Index DTC Recirculation Detection Item Page Indication Blinks 7 An open in the air mix c
54. st results Related symptoms Probable cause Remedy Discharge high After stopping compressor pressure Air in system Recover evacuate see page 21 54 pressure abnormally high drops quickly and then continues to fall gradually and recharge with specified amount see page 21 55 Reduced or no air flow through Clogged condenser or radiator Clean Faulty compressor seal condenser fins Check fan voltage and rpm Condenser or radiator fan not Check fan direction working properly Line to condenser is excessively hot Restricted flow of refrigerant in Replace restricted lines system Discharge pressure High and low pressures balanced Faulty compressor discharge Replace the compressor abnormally low soon after stopping compressor Low valve side is higher than normal Outlet of expansion valve is not frosted low pressure gauge indicates vacuum Faulty expansion valve Moisture in system Replace the expansion vaive Recover evacuate for at least 30 minutes and recharge with specified amount Suction low pressure abnormally low Expansion valve is not frosted and low pressure line is not cold Low pressure gauge indicates vacuum i Frozen expansion valve Moisture in system Faulty expansion valve Recover evacuate for at least 30 minutes and recharge with specified amount Replace the expansion valve Discharge temperature is l
55. the 5P connector from the recirculation control motor 1 Remove the ECM see page 11 4 NOTICE incorrectly applying power and ground to 2 Remove the relay mount bracket bolt and move the recirculation control motor will damge it the relays out of the way Follow the instructions carefully 3 Disconnect the 5P connector A from the 2 Connect battery power to the No 5 terminal of the recirculation control motor Remove the self recirculation control motor and ground the No 1 tapping screws and the recirculation control motor and No 2 terminals the recirculation control motor from the blower unit should run smoothly To avoid damaging the recirculation control motor do not reverse power and ground Disconnect the No 1 or No 2 terminals from ground the recirculation control motor should stop at Fresh or Recirculate Don t cycle the recirculation control motor for a long time RECIRCULATION CONTROL MOTOR 4 Install the motor in the reverse order of removal Make sure the pin on the motor is properly engaged with the linkage After installation make sure the motor runs smoothly 3 If the recirculation control motor does not run in step 2 remove it then check the recirculation control linkage and doors for smooth movement If the linkage and doors move smoothly replace the recirculation control motor If the linkage or doors stick or bind repair them as needed 21 36 b e Evaporator
56. ts are located in this is less than usual area Review the SRS component locations see page 23 13 and precautions and procedures see page 23 14 1 Open the glove box Remove both glove box stops in the SRS section before performing repairs or service then let the glove box hang down see page 20 63 1 Make sure you have the anti theft code for the radio 2 Remove the filter tid A from the blower unit then then write down the frequencies for the preset pull out the first dust and pollen filter B Slide the buttons second filter to the left and pull it out 2 Disconnect the battery negative cable and wait 3 minutes before beginning work 3 Remove the right kick panel see page 20 50 passenger s dashboard lower cover and the glove box see page 20 63 4 Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown Remove and discard the plastic cross brace 3 Remove the filter A from the housing B and replace the filter Cut 4 Install the filters in the reverse order of removal 21 39 Heating and Air Conditioning Blower Unit Removal and Installation cont d 5 Remove the steering hanger beam bracket cover from the right side of the glove box opening then remove the bolts and the glove box frame 6 Remove the ECM see page 11 4 7 Remove the EPS control unit see page 17 67 8 Disconnect and remove the PGM FI main re
57. ween body ground and heater control panel connector B 22P terminal No 6 HEATER CONTROL PANEL CONNECTOR 14 Wire side of female terminals HEATER CONTROL PANEL CONNECTOR B 22 PNK BLK 31415 19 f 0 2 2 Wire side of female terminals 18 there continuity YES Repair any short to body ground in the wire s between the heater control panel and the air mix control motor li to step 5 e 5 Turn the ignition switch ON 1 and check the same terminals for voltage HEATER CONTROL PANEL CONNECTOR A 14P Wire side of female terminals HEATER CONTROL PANEL CONNECTOR B 22P E PNK BLK PAZ Wire side of female terminals 15 there any voltage YES Repair any short to power in the wire s between the heater control panel and the air mix control motor This short may also damage the heater control panel Repair the short to power before replacing the heater control panel NO Substitute a known good air mix control motor and recheck If the symptom indication goes away replace the original air mix control motor If the symptom indication continues substitute a known good heater control panel and recheck if the symptom indication goes away replace the original heater control panel W DTC 9 A Problem in the Air Mix Control Linkage Door or Motor 1 Test the
58. y 3 Disconnect the suction and receiver lines from the evaporator core see page 21 42 4 From under the hood open the cable clamp A then disconnect the heater valve cable B from the heater valve arm C Turn the heater valve arm to the fully opened position as shown 5 When the engine is cool drain the engine coolant from the radiator see page 10 6 Slide the hose clamps A back then disconnect the inlet heater hose B and the outlet heater hose C from the heater core Engine coolant will run out when the hoses are disconnected drain it into a clean drip pan Be sure not to let coolant spill on the electrical parts or the painted surfaces If any coolant spills rinse it off immediately Remove the bolt and the heater valve then remove the mounting nut from the heater unit Take care not to damage or bend the fuel lines and the brake lines etc 8x 1 25 mm 12 N m 1 2 kgf m 8 7 cont d 21 43 Heating and Air Conditioning Heater Unit Core Replacement cont d 14 8 Remove the dashboard see page 20 66 11 Remove the mounting bolts the mounting nuts and the heater unit 9 Disconnect the connectors A from the blower 1 i 6x 1 0 mm motor the recirculation control motor the mode 9 8 Nm 1 0 kgf m 7 2 control motor and the power transistor then remove the wire harness clips B and the t oa connector C Remove the self tapping screws an

02-03 Honda Civic Si Service Manual

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