Honda Civic manuals

Honda Civic Service Manual: Heater Unit/Core Removal and Installation (With A/C)

Honda Civic Service Manual / HVAC / Cooling / Heater Unit/Core Removal and Installation (With A/C)


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.


SRS components are located in this area. Review the SRS component locations and the precautions and procedures before doing repair or servicing.


NOTE:

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. Vehicle Lift

1.

Raise the vehicle on a lift, and make sure it is securely supported.


2. Battery Terminal (SRS) - Disconnection


1.

Make sure the ignition switch is in LOCK (0).


2.

Disconnect and isolate the negative cable with the battery sensor (A) from the battery.


NOTE:

Always disconnect the negative side first.

To protect the battery sensor connector (B) from damage, do not hold it when removing the negative terminal.

Do not disconnect the battery sensor from the negative terminal (C).


3.

Disconnect the positive cable (D) from the battery.


4.

Wait at least 3 minutes before starting work.


3. R-134a Refrigerant Recovery/Recycling/Charging Station - Connection

1.

Connect an 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.


4. A/C Refrigerant - Recovery

1.

Recover the refrigerant from the A/C system.


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.


5. Wiper Arm Assembly (K24Z7 engine)


NOTE: Set the wiper arms to the auto-stop position before removal.


1.

Remove the cowl top wiper covers (A).


2.

Remove the wiper arms (B).


6. Both Side Cowl Covers (K24Z7 engine)


1.

Remove the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


7. Center Cowl Cover (K24Z7 engine)


1.

Remove the center cowl cover (A).


2.

Disconnect the windshield washer tube (B).


3.

If necessary, remove the hood rear seal (C).


8. Under-Cowl Panel (K24Z7 engine)

1.

Remove the under-cowl panel (A).


9. A/C Line - Evaporator Side

Except K24Z7 engine

1.

Except K24Z7 engine; Remove the bolts.


K24Z7 engine

2.

K24Z7 engine; Remove the bolt.


Flange bolt type


Stud bolt type

3.

Disconnect the A/C line (A).


4.

Stud bolt type; Remove the stud bolt (A).


10. Radiator Cap

1.

Wait until the engine is cool, then carefully remove the radiator cap.


11. Radiator Coolant - Replacement

1.

Loosen the drain plug (A), and drain the coolant.


12. Heater Hose - Body Side


NOTE:

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.

Note the layout of the hose.


1.

Disconnect the inlet heater hose (A).


2.

Disconnect the outlet heater hose (B).


3.

Remove the nut.


NOTE: Take care not to damage or bend the fuel lines or brake lines, etc.


13. Front Door Opening Seal As Needed Both


1.

Remove front door opening seal (A) as needed.


2.

Repeat on the opposite side.


14. A-Pillar Trim Both

1.

Pull out the A-pillar trim (A) to release the clips.


2.

Put a shop towel (A) in the opening between the A-pillar trim (B) and the dashboard to prevent dropping the A-pillar clips.


3.

Disconnect the connector (A), then remove the A-pillar trim (B).


NOTE: The upper clip (C) will stay in the body.



4.

Remove the upper clip (A) from the body.


5.

Repeat on the opposite side.


15. Driver's Dashboard Lower Cover

1.

Remove the driver's dashboard lower cover (A).


16. Both Front Door Sill Trims


1.

Driver's side: Remove the cap (A) from the front door sill trim (B).


2.

Driver's side: Remove the opener lock cylinder (C).


3.

Driver's side: Remove the screw (A).


Driver's side


Passenger's side

4.

Remove both front door sill trims (A).


17. Both Kick Panels

Driver's side


Passenger's side


1.

Pull out both front door opening seals (A) as needed.


2.

Remove both kick panels (B).


18. Glove Box - Move

1.

Lower the glove box (A).


19. M/T Shift Lever Knob

Except K24Z7 engine


1.

Except K24Z7 engine: Lower the shift lever boot (A) to release the hooks from the boot.


2.

Except K24Z7 engine: Remove the shift lever knob (B).


K24Z7 engine


3.

K24Z7 engine: Lower the shift lever boot (A) to release the hooks from the boot.


4.

K24Z7 engine: Loosen the shift lever boot ring (B).


5.

K24Z7 engine: Remove the shift lever knob (C).


6.

K24Z7 engine: Remove the shift lever boot ring.


20. Center Console Panel


1.

Detach the clips (A).


2.

Remove the center console panel (B).


3.

For some models: Disconnect the connector(s) (C).


21. Center Console Panel Assembly (Except '12M M/T)

1.

Detach the clips (A).



2.

Remove the center console panel (A).


3.

For some models: Disconnect the connector(s) (B).


22. Cup Holder Panel Assembly

1.

Remove the cup holder panel assembly (A).


23. Center Console


1.

Remove the bolts (A).


2.

Disconnect the connector (B).



3.

Remove the console box mat (A).


4.

Remove the bolts (B).


5.

Disconnect the connector (A).


6.

Remove the center console (A).


24. Rear Heater Joint Duct

1.

Remove the rear heater joint duct (A).


25. Driver's Airbag


1.

Remove the access panel (A).


2.

Disconnect the driver's airbag inflator connector (B) on the cable reel harness.


3.

Disconnect the horn switch connector (C).



4.

Remove the TORX bolts using a TORX T30 bit.


5.

Remove the driver's airbag (A).


26. Steering Wheel Assembly

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1.

Set the front wheels in the straight ahead position.


2.

Disconnect the connector (A).


3.

Loosen the steering wheel bolt (B) three turns.



4.

Install a commercially available steering wheel puller (A) on the steering wheel (B).


5.

Free the steering wheel from the steering column shaft by turning the pressure bolt (C) of the puller.


Note these items when removing the steering wheel:

Do not tap on the steering wheel or the steering column shaft when removing the steering wheel.

If you thread the puller bolts (D) into the wheel hub more than five threads, the bolts will hit the cable reel and damage it. To prevent this, install a pair of jam nuts five threads up on each puller bolt.



6.

Remove the steering wheel puller.


7.

Remove the steering wheel (A) from the steering column.


27. Upper Column Cover

1.

Remove the upper column cover (A).


28. Lower Column Cover

1.

Remove the screws (A).


2.

Remove the lower column cover (A).


29. Combination Switch Body Assembly


1.

Disconnect the connectors (A).


2.

Remove the clip (B).


3.

Disconnect the connectors (A).


Without steering lock


With steering lock

4.

Remove the combination switch body assembly (A) from the steering column shaft.


30. Steering Joint Cover

1.

Remove the steering joint cover (A).


31. Steering Column Lower Slide Shaft - Hold


1.

Set the steering column to the center tilt position, and to the center telescopic position.


2.

Hold the lower slide shaft (A) on the column with a piece of wire (B) between the joint yoke (C) of the lower slide shaft and the joint yoke (D) of the upper shaft to prevent the lower slider shaft from pulling out.


32. Steering Joint - Disconnection


1.

Remove the steering joint bolt (A).


2.

Disconnect the steering joint (B) from the pinion shaft.


NOTE:

If the center guide (C) is in place and has not moved, leave it in place.

If the center guide has come off, discard it.


33. Steering Column

1.

With steering lock: Disconnect the connectors (A) from the ignition switch (B).


Without steering lock


With steering lock


2.

Detach the wire harness clips (C) from the steering column.


3.

Remove the steering column (D).


NOTE: Do not release the lock lever until the steering column is installed. If the lock lever is released before installation, adjust the steering column after installation.


34. A-Pillar Corner Trim Both

1.

Remove both A-pillar corner trims (A).


35. Dashboard/Steering Hanger Beam

1.

Disconnect the connector (A).


2.

Disconnect the connectors (A).


3.

Remove the bolts (A, B) from under the dash.


4.

With climate control: Remove the aspirator hose (A).



5.

Disconnect the connectors (A).


6.

Remove the bolts (B).


7.

Disconnect the connector (A).


8.

Disconnect the connector (A).



9.

Remove the caps (A).


10.

Loosen the special bolts (B) until they disengage from the threads on the hanger beam side brackets (C), and engage the inside threads of the collar bolts (D). The thread lock on the special bolts makes the special bolts and the collar bolts turn together.


11.

Continue to loosen the special bolts to turn the collar bolts into the fixed space adjusters (E) until the collar bolts engage the adjuster brackets. This creates a gap (F) between the collar bolts and the body.


12.

Remove the special bolts.


13.

Check that the collar bolts (A) are seated in the fixed space adjusters (B).


NOTE: If either collar bolt was not seated, replace the special bolts.



14.

Remove the caps (A).


15.

Remove the bolts (B).


16.

Remove the dashboard (A).


36. Blower-Heater Unit

1.

Disconnect the connector (A).


2.

Remove the blower-heater unit (A).


37. A/C Wire Harness


1.

Remove the blower motor cover (A).


2.

Disconnect the connector (B).


3.

Remove the harness clip (C).



4.

Disconnect the connector (A).


5.

Remove the clips (B).


6.

Disconnect the connectors (A).



7.

Disconnect the connector (A).


8.

Remove the harness clip (B).


38. Blower Unit

1.

Remove the blower unit (A).


39. Passenger's Heater Duct

1.

Remove the passenger's heater duct (A).


40. Heater Core Cover

1.

Remove the heater core cover (A).


41. Expansion Valve Cover

1.

Remove the expansion valve cover (A) and the seal (B).


42. Heater Core


1.

Remove the heater pipe bracket (A).


2.

Remove the grommet (B).


3.

Carefully pull out the heater core (C).



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.

Do not operate the leak detector near flammable vapors. Its sensor operates at high temperatures, and could ignite the vapors, resulting in personal injury and/or damage to the equipment.


SRS components are located in this area. Review the SRS component locations and the precautions and procedures before doing repair or servicing.


NOTE:

If an 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.

Check the system for leaks using an R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better.

Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely.

Make sure that there is no coolant leakage.

Make sure that there is no air leakage.


1. Heater Core


1.

Carefully install the heater core (A).


2.

Install the grommet (B).


3.

Install the heater pipe bracket (C).


2. Expansion Valve Cover

1.

Install the expansion valve cover (A) and the new seal (B).


3. HEATER CORE COVER

1.

Install the heater core cover (A).


4. Passenger's Heater Duct

1.

Install the passenger's heater duct (A).


5. Blower Unit

1.

Install the blower unit (A).


6. A/C Wire Harness


1.

Connect the connector (A).


2.

Install the harness clip (B).


3.

Connect the connectors (A).



4.

Connect the connector (A).


5.

Install the clips (B).



6.

Connect the connector (A).


7.

Install the harness clip (B).


8.

Install the blower motor cover (C).


7. Blower-Heater Unit

1.0mm[loo

1.

Install the blower-heater unit (A).


2.

Connect the connector (A).


8. Dashboard/Steering Hanger Beam

Special bolt tightening on passenger's side

mm22(2.2

NOTE:

Make sure the collar bolts (A) turn easily by hand in the fixed space adjusters (B). Tighten the collar bolts by hand until they engage the fixed space adjusters before reinstalling the dashboard.

Before reinstalling the dashboard, screw the special bolts (C) into the collar bolts, and check that they turn together. If they do not turn together, replace the special bolts.


1.

Install the dashboard (A).



2.

Install the bolts (A).


3.

Install the caps (B).



4.

Install the special bolts (A).


5.

Install the caps (B).


6.

Connect the connector (A).


7.

Connect the connector (A).


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8.

Connect the connectors (A).


9.

Install the bolts (B).


10.

With climate control: Install the aspirator hose (A).


ixi2mm22(2.2asin

11.

Install the bolts (A, B) under the dash.


12.

Connect the connectors (A).


13.

Connect the connector (A).


9. A-Pillar Corner Trim Both

1.

Install both A-pillar corner trims (A).


10. Steering Column

1.

Install the steering column (A).


NOTE: Do not release the lock lever until the steering column is installed. If the lock lever is released before installation, adjust the steering column after installation.


Without steering lock

22(22mm)


With steering lock

u.


2.

Loosely tighten the attaching nuts and bolts.


3.

Tighten the attaching nuts and bolts to the specified torque in the sequence shown.


4.

Install the wire harness clips (B) to the steering column.


5.

With steering lock: Connect the connectors (C) to the ignition switch (D).


11. Steering Joint - Reconnection


1.

Set the rack in the straight ahead driving position.


2.

Slip the lower end of the steering joint (A) onto the pinion shaft (B).


NOTE:

Pinion shaft with center guide: Install the steering joint by aligning the center guide (C).

Pinion shaft without center guide: Position the steering column by aligning the gap (D) within the angle.



3.

Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft.


4.

Loosely install the steering joint bolt (C).


5.

Be sure that the joint bolt is securely in the groove in the pinion shaft.


6.

Pull on the steering joint to make sure that the steering joint is fully seated.


12. Steering Column Lower Slide Shaft - Release

1.

Cut the wire (A).


13. Steering Joint Cover

1.

Install the steering joint cover (A) in the sequence shown.


14. Combination Switch Body Assembly

Without steering lock


With steering lock


1.

Install the combination switch body assembly (A).


2.

Tighten three screws (B) in the sequence shown.


3.

Connect the connectors (A).



4.

Connect the connectors (A).


5.

Install the clip (B).


15. Lower Column Cover

1.

Install the lower column cover (A).


2.

Install the screws (A).


16. Upper Column Cover

1.

Install the upper column cover (A).


17. Steering Wheel Assembly


1.

Make sure the front wheels are pointing straight ahead.


2.

Center the cable reel (A). Do this by first rotating the cable reel clockwise until it stops.


3.

Rotate the cable reel counterclockwise about three full turns. The arrow mark (B) on the cable reel label should point straight up.



4.

Position the steering wheel hub (A) so that it engages the pin (B) of the cable reel.


5.

Install the steering wheel (C) on to the steering column shaft.


NOTE: Do not tap on the steering wheel or the steering column shaft when installing the steering wheel.


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6.

Install the steering wheel bolt (A), and tighten it to the specified torque.


7.

Connect the connector (B).


8.

Make sure the wire harness is routed and fastened properly.


18. Driver's Airbag


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NOTE: If you are replacing a deployed driver's airbag, inspect the cable reel for heat damage. If there is any damage, replace the cable reel.


1.

Place the driver's airbag (A) in the steering wheel.


2.

Tighten the new TORX bolts using a TORX T30 bit.


NOTE: Make sure the clearance (B) between the steering wheel and horn pad is the specified value.



3.

Connect the driver's airbag inflator connector (A) on the cable reel harness.


4.

Connect the horn switch connector (B).


NOTE: After reconnecting the negative cable to the battery, make sure the horn works properly.


5.

Install the access panel (C).


19. Rear Heater Joint Duct

1.

Install the rear heater joint duct (A).


20. Center Console

1.

Install the center console (A).


2.

Connect the connector (A).



3.

Install the bolts (A).


4.

Install the console box mat (B).



5.

Connect the connector (A).


6.

Install the bolts (B).


21. Cup Holder Panel Assembly

1.

Install the cup holder panel assembly (A).


22. Center Console Panel Assembly (Except '12M M/T)


1.

For some models: Connect the connector(s) (A).


2.

Install the center console panel (B).


3.

Install the clips (A).


23. Center Console Panel


1.

For some models: Connect the connector(s) (A).


2.

Install the center console panel (B).


3.

Install the clips (C).


24. M/T Shift Lever Knob

Except K24Z7 engine


1.

Except K24Z7 engine: Install the shift lever knob (A).


NOTE: Tighten the shift lever knob until the shift pattern is properly aligned.


2.

Except K24Z7 engine: Connect the shift lever boot (B).


K24Z7 engine


3.

K24Z7 engine: Install and turn the shift lever boot ring (A) until it reaches the bottom of the threads on the shift lever.


4.

K24Z7 engine: Turn the shift lever knob (B) until the shift lever knob contacts the shift lever boot ring.


5.

K24Z7 engine: Tighten the shift lever boot ring and the shift lever knob together with the shift pattern properly aligned.


6.

K24Z7 engine: Connect the shift lever boot (C).


25. Both Kick Panels

Driver's side


Passenger's side


1.

Install both kick panels (A).


2.

Install both front door opening seals (B) as needed.


26. Both Front Door Sill Trims

Driver's side


Passenger's side

1.

Install both front door sill trims (A).


2.

Driver's side: Install the screw (A).



3.

Driver's side: Install the opener lock cylinder (A).


4.

Driver's side: Install the cap (B) to the front door sill trim (C).


27. Driver's Dashboard Lower Cover

1.

Install the driver's dashboard lower cover (A).


28. A-Pillar Trim Both

1.

Carefully install the new upper clip (A) to the A-pillar trim (B).



2.

Connect the connector (A).


3.

Fit the clips into the holes in the A-pillar.


4.

Lightly push the A-pillar trim (B) into place, then install the trim.


NOTE:

Make sure the side curtain airbag is not tucked under the clips or the trim ribs.

Do not push too hard on the A-pillar trim. If you push too hard, the clip will be damaged, and it will not hold the trim properly.

Gently tug on the A-pillar trim to verify that all clips are securely fastened.


5.

Repeat on the opposite side.


29. Front Door Opening Seal as Needed Both


1.

Install front door opening seal (A).


2.

Repeat on the opposite side.


30. Heater Hose - Body Side

mm11(1.1

1.

Install the nut.


NOTE: Take care not to damage or bend the fuel lines or brake lines, etc.



2.

Connect the inlet heater hose (A).


3.

Connect the outlet heater hose (B).


31. A/C Line - Evaporator Side

1.

Stud bolt type; Install the stud bolt (A).


Stud bolt type

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Flange bolt type

2.

Connect the A/C line (A) with new O-rings (B) that are lubricated with clean refrigerant oil.


Except K24Z7 engine

an

3.

Except K24Z7 engine; Install the bolts.


K24Z7 engine

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4.

K24Z7 engine; Install the bolt.


32. Under-Cowl Panel (K24Z7 engine)

1.

Install the under-cowl panel (A).


33. Center Cowl Cover (K24Z7 engine)


1.

If necessary, install the hood rear seal (A).


2.

Connect the windshield washer tube (B).


3.

Install the center cowl cover (C).


34. Both Side Cowl Covers (K24Z7 engine)


1.

Install the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


35. Wiper Arm Assembly (K24Z7 engine)

NOTE: Set the wiper arms to the auto-stop position before installation.


1.

Install the wiper arms (A).


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2.

Install the cowl top wiper covers (B).


36. Battery Terminal (SRS) - Reconnection

(o.2ao.sam.


NOTE: If the battery performs abnormally, test the battery.


1.

Clean the battery terminals.


2.

Connect the positive cable (A) to the battery.


NOTE: Always connect the positive side first.


3.

Connect the negative cable and the battery sensor (B) to the battery.


NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal.


4.

Apply multipurpose grease to the terminals to prevent corrosion.


37. Radiator Coolant - Replacement

1.

Follow the chart and pour coolant into the radiator up to the base of the filler neck.


NOTE:

Use Honda Long Life Antifreeze/Coolant Type 2, and if necessary add Honda Extreme Cold Weather Antifreeze/Coolant Type 2 (concentrate). Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail.

Honda Long Life Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Honda Extreme Cold Weather Antifreeze/Coolant Type 2 is a 100 % concentration coolant. Do not add water to either coolant.

If the vehicle is regularly driven in very low temperatures (below -22 °F ( -30 °C)), a 60 % concentration of coolant should be used.


Operation

Vehicle Usage (Desired Mixture)

Current Mixture

Coolant Drain

Add Amount of Honda Extreme Cold Weather Antifreeze/Coolant Type 2 (100 % concentrate)

Then add Honda Long Life Antifreeze/Coolant Type 2 (50/50)

Coolant Change

Normal Area (50/50)

50/50
60/40
unknown

Drain radiator, engine block, and reservoir

None

Top off the cooling system

Very Cold Area (60/40)

50/50
unknown

Drain radiator, engine block, and reservoir

About 1.3 L (44 fl oz)

60/40

About 1.2 L (41 fl oz)

Engine Overhaul

Normal Area (50/50)

-

-

None

Very Cold Area (60/40)

-

-

About 1.2 L (41 fl oz)

Coolant Winterizing

Very Cold Area (60/40)

50/50

Drain about 2.0 L (68 fl oz) from radiator

About 1.2 L (41 fl oz)

unknown*

Drain radiator, engine block, and reservoir


*: When you want to winterize the coolant with the minimum amount of coolant change but the current coolant concentration in the vehicle is unknown, you must drain all coolant from the cooling system.


Engine Coolant Capacities (Including the coolant reservoir capacity of 0.475 L (0.1255 US gal))


Except K24Z7 engine

 

Manufacturer

Capacity

At Coolant Change

DENSO

5.59 L (1.477 US gal)

TRAD

5.50 L (1.453 US gal)

After Engine Overhaul (M/T)

DENSO

6.42 L (1.696 US gal)

TRAD

6.33 L (1.672 US gal)

After Engine Overhaul (A/T)

DENSO

6.56 L (1.732 US gal)

TRAD

6.47 L (1.709 US gal)

After Engine Overhaul (CVT)

DENSO

6.52 L (1.722 US gal)

TRAD

6.43 L (1.699 US gal)


Engine Coolant Capacities (Including the coolant reservoir capacity of 0.475 L (0.1255 US gal))


K24Z7 engine

 

Capacity

At Coolant Change

5.5 L (1.45 US gal)

After Engine Overhaul

6.7 L (1.78 US gal)


38. A/C System Evacuation

1.

Evacuate the system. The vacuum pump should run for a minimum of 30 minutes to eliminate all moisture from the system. When the suction gauge reads -93.3 kPa (-700 mmHg, -27.55 inHg) for at least 30 minutes, close all valves, and turn off the vacuum pump.


2.

If the suction gauge dose not reach approximately -93.3 kPa (-700 mmHg, -27.55 inHg) in 15 minutes, there is probably a large leak in the system. Partially charge the system, and check for leaks.


39. A/C Refrigerant - Charging

1.

Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the A/C compressor will be damaged.


Select the appropriate units of measure for your refrigerant charging station.


Refrigerant Capacity:

375 to 425 g

13.2 to 15.0 oz

0.375 to 0.425 kg

0.827 to 0.937 lbs


40. A/C Refrigerant - Leak Check

Leak Detector Usage Tips (Refer to the Operator's Manual for complete operating instructions)


Position the vehicle in a wind-free work area. This will aid in detecting small leaks.

When using the leak detector for the first time, allow it to warm up for 2 minutes with the probe in a clean atmosphere. This lets the temperature sensor in the detector stabilize.

The calibration check should be done in the ‘‘Search 2’’ mode. Once that is done, the other check modes do not need calibrating.

When leak checking through the HVAC module drain hose, avoid drawing water into the probe. Water can damage the internal pump and sensor.

Avoid creasing the flexible probe extension. Creases can restrict air flow and give false readings.

Because the detector recalibrates itself for ambient gases, it may be necessary to move the detector away from the leak to clear the sensor. Once the sensor has cleared, recheck the suspected leak.

When removing the clear probe tip, be careful not to lose the flow ball.

R-134a is heavier than air; always check below and to the sides of all potential leak sources.

Halogen leak detectors are sensitive to chemicals: windshield washing solutions, solvents/cleaners, and some vehicle adhesives. Keep these chemicals out of the area when doing leak detection.


Fluorescent Dye Usage Tips


Use only Tracer-Stick single dose fluorescent dye capsules from Tracerline®. Other dyes contain solvents that may contaminate the refrigerant oil, leading to component failure.

Adding excessive amounts of dye can damage the A/C compressor.

PAG oil is water soluble, so condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.

After checking and repairing leaks, thoroughly clean any residual dye from the areas where leaks were found. Use GLO-AWAY dye cleaner, from Tracerline®, and hot water to remove the dye (follow the instructions on the bottle). Residual dye stains can cause misdiagnosis of any future A/C system leaks.

If any refrigerant dye contacts an exterior paint surface, remove it by doing this:


Carefully wash the affected surfaces to remove any dirt, and to prevent paint scratching.

Mix water and isopropyl alcohol in a 50/50 mixture. Soak a soft 100 % cotton towel with the water/alcohol mixture, and place the cloth on the affected areas to remove the dye.

After removing the dye with the water/alcohol-soaked cloth, carefully wash the affected areas, and check that there is no remaining dye.


1.

With the engine OFF, use a halogen leak detector first to detect the leak source. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test the following areas of the system for leaks:


Possible Leak Area

Diagnostic Procedure with the Leak Detector

Notes

Service ports

Check the service ports with caps installed

If the detector ‘‘sniffs’’ a leak, use fluorescent dye to confirm it

When capping the service ports, ensure that the seals on the port caps are in place, and that the caps are tight. The caps are used as the final seals in the system

A/C condenser

If the detector ‘‘sniffs’’ a leak, use fluorescent dye to confirm it

Check for joints or connections coated with oily dust

Check for damaged and corroded areas

Check all fittings, couplings, brazed/welded areas and areas around attachment points

Move the probe slowly (1 in/second or less), and keep it within 1/4 in of the component being checked. This maximizes the chance of detecting a leak

If you detect a leak, blow compressed air over the area, then recheck for leaks. For large leaks, clearing the area with compressed air may help you pinpoint the leak source

Evaporator

Check at the evaporator drain hose

Check at the passenger's side vent and turn the blower on low speed

 

A/C lines

Wiggle the rubber hoses when checking crimped metal ends

If the detector ‘‘sniffs’’ a leak, use fluorescent dye to confirm it

Check all fittings, couplings, pressure switches, brazed/welded areas, and areas around attachment points on A/C lines and components

Check for damaged and corroded areas

Move the probe slowly (1 in/second or less), and keep it within 1/4 in of the component being checked. This maximizes the chance of detecting a leak


2.

Close the quick coupler valves, then disconnect the quick couplers from the vehicle service ports.


3.

Attach the universal connect set, from the Optimax Jr. Leak Detection Kit, to the service valve fitting. Close the control valve (the black knob on the connect set).


4.

Attach the charging station low pressure hose quick coupler to the service valve fitting, and open the quick coupler valve. Evacuate the connect set using the charging station vacuum pump, then close the quick coupler valve.


5.

Detach the universal connect set, and install a Tracer-Stick® dye capsule between the connect set and the service valve fitting (see the manufacturer's instructions for more detail).


6.

Attach the quick coupler on the universal connect set to the low pressure service port on the vehicle. Open the charging station low pressure hose quick coupler valve, but do not open the control valve.


7.

Start the engine, and set the A/C system to maximum cooling. Open the control valve to let refrigerant and the dye enter the A/C system through the low pressure service port. Close the control valve when the Tracer-Stick® dye capsule is empty.


8.

Run the engine and A/C system for 15 minutes to thoroughly circulate the dye. Then shut the engine off, and inspect the following areas of the system for leaks:


NOTE:

Check for leaks in a dark work area, and use the UV light and the special glasses from the leak check kit. Other UV lights may not work well with the Tracer-Stick® dye.

Small leaks may take up to 1 week of vehicle operation (with normal A/C use) to become visible.


Possible Leak Area

Diagnostic Procedure with Fluorescent Dye

Service ports

If a leak is found, replace the cap/O-ring seal or A/C line as needed

A/C lines

Use a permanent marker pen to circle the leak area

If a leak is found, remove and replace the A/C line

A/C condenser

If a leak is found, remove the A/C condenser

Determine whether leak is in the A/C condenser or the receiver/dryer

Use a permanent marker pen to circle the leak area

Replace either the receiver/dryer, or the A/C condenser, depending upon which is leaking

A/C compressor

Check for leaks at all of the A/C compressor joints, the clutch center, the A/C compressor front housing bolts, and the scroll bolts on the back of the A/C compressor

If a leak is found, use a permanent marker pen to circle the leak area

If the A/C compressor relief valve appears to be leaking, determine whether the leak is coming from the relief valve, or the joint between the A/C compressor casing and the valve. If the leak is from the relief valve, check the A/C system pressures, and refer to the pressure test table in the A/C system test. If the leak is from the casing/valve joint, replace the A/C compressor relief valve

If the leak is coming from the suction hose and/or discharge hose fittings on the A/C compressor, clean the A/C fittings and replace the suction/discharge fitting O-rings

For all other A/C compressor leaks, remove and replace the A/C compressor

Evaporator

Start checking for evaporator leaks by illuminating the evaporator drain tube area

If a leak is found, remove the evaporator core

Determine whether leak is from evaporator or expansion valve

Use a permanent marker pen to circle leak area

Replace the expansion valve, or the evaporator core, depending upon which is leaking


41. HDS DLC - Connection


1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.


2.

Turn the ignition switch to ON (II).


3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.


42. DTC - Clear

1.

Clear the DTC(s) by following the screen prompts on the HDS.


2.

Turn the ignition switch to LOCK (0), then wait for 10 seconds.


43. Confirm Proper SRS Operation

Turn the ignition switch to ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.


44. A/C System - Test


1.

Insert a thermometer (A) in the center vent.


2.

Place a hygro-thermometer (B) near the blower unit's recirculation inlet duct.


3.

Test conditions:


Move the vehicle out of direct sunlight and let it cool down to the surrounding (ambient) temperature. If necessary, wash the vehicle to cool it down more quickly.

The blower intake temperature must be at least 68 °F (20 °C).

Open the hood.

Open the front doors.

Start the engine.

Set the temperature control dial or temperature control button to MAX COOL, the mode control button to VENT, and the recirculation control button to RECIRCULATE.

Set the A/C button on and the fan control dial or fan control button to Max.

Run the engine at 1,500 rpm.

No driver or passengers in vehicle.


4.

Inspect the A/C components for the following conditions:


A/C compressor clutch not engaged.

Abnormal frost areas.

Unusual noises.


If you observe any of these conditions, refer to the Symptom Troubleshooting Index.


5.

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 blower intake temperature near the blower unit, and the discharge (high) and suction (low) pressures on the A/C gauges.


6.

To complete the vent (delivery)/blower intake temperature chart:


Mark the vent (delivery) temperature on the vertical line.

Mark the blower intake temperature on the bottom line.

Draw a vertical line from the blower intake temperature mark.

Draw a horizontal line from the vent (delivery) temperature mark until it intersects the vertical line.


NOTE: The vent (delivery) temperature and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection.

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7.

To complete the high side (discharge) pressure/blower intake temperature chart:


Mark the high side (discharge) pressure on the vertical line.

Mark the blower intake temperature on the bottom line.

Draw a vertical line from the blower intake temperature mark.

Draw a horizontal line from the high side (discharge) pressure mark until it intersects the vertical line.


NOTE: The high side (discharge) pressure and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection.

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8.

To complete the low side (suction) pressure/blower intake temperature chart:


Mark the low side (suction) pressure along the vertical line.

Mark the blower intake temperature along the bottom line.

Draw a vertical line from the blower intake temperature mark.

Draw a horizontal line from the low side (suction) pressure mark until it intersects the vertical line.


NOTE: The low side (suction) pressure and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection.

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45. Glove Box - Move

1.

Install the glove box (A).


46. VSA Sensor Neutral Position - Memorization

1.

Park the vehicle on a flat and level surface, with the steering wheel in the straight ahead position.


2.

Select VSA ADJUSTMENT, then select ALL SENSORS with the HDS, and follow the screen prompts.


NOTE: See the HDS Help menu for specific instructions.


47. Steering Angle Sensor Neutral Position - Clear

1.

Select EPS ADJUSTMENT, then select EPS STEERING ANGLE SENSOR VALUE CLEAR and follow the screen prompts on the HDS.


NOTE: See the HDS Help menu for specific instructions.


48. Maintenance Minder Reset

1.

After doing all procedures, select the individual maintenance item you wish to reset with the HDS..


A/C System Inspection
Inspection 1. A/C System Inspection checkin! NOTE: For A/C system noise, go to the A/C System Noise Check. ...

A/C Condenser Removal and Installation ('13)
1. Glove Box - Move 1. Lower the glove box (A). 2. R-134a Refrigerant Recovery ...

See also:

Honda Civic Owners Manual. Maintaining the Bumpers and Other Resin Coated Parts
If you get gasoline, oil, engine coolant, or battery fluid on resin coated parts, they may be stained or the coating may peel. Promptly wipe it away using a soft cloth and clean water. Maintaining the Bumpers and Other Resin Coated Parts Ask a dealer about the correct coatin ...

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