1994 HONDA INTEGRA Workshop Manual

A/C Service Tips and Precautions
The air conditioner system uses HFC-134a (R-134a) .efrigerant and polyalkyleneglycol (PAG) retrigerant oil (ND-OIL g: p/N
38899 - PR7 - A0l ), which are not compatible with CFC-12 \R-'12) refrigerant and mineral oil. Do not use R-12 refrigerant ormineral oil in this system, and do not attempt to use R-'12 servicing equipment; damage to the air conditioner system oryour servicing equipment will result.
only use service equipment that is u.L,-listed and is certified to meet the requirements of sAE J2210 to remove R-134afrom the air conditioner svstem.
CAUTION: Exposure lo air conditioner refrigorant and lubricanl vapor or mi3t cln irritato gyos, nose and throat. Avoidbreathing lhe air conditioner refrigerant and lubricant vapor or mist.
lf accidental system discharge occurs, ventilate work area befor€ resuming service.R-134a service equipment or vehicle air conditioner systems should not be pressure tested or leak tested with compressedair.
@ some mirtures of air and R-l3ifa have been 3hown to be combu3tible at slsvated prossuros and can relultin fire or explosion causing inlury or property damage. Never use complessod ai. to prgssure t€|st R-134a service equip-ment or vehicle air conditiongr systems.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.'1. Always disconnect the negative cable from the battery whenever replacing air conditioning pans.
2. Keep moisture and dust out of the system. When disconnecting any lines, plug or cap the fittings immediately; don'tremove the caps or plugs until just before you reconnect each line.
3. Before con necting a ny hose or line, apply a few drops of refrigerant oil (ND-OIL 8: P/N 38899 - PR7 - AO1) to the O-ring.4. When tightening or loosening a fitting, use a second wrench to support the matching fitting.5. When recovering the system, use a R-134a refrigerant Recovery/Recycling/Charging System; don't release refrigerantinto the atmosDhere.
6. Add refrigerant oil (ND-OlL 8: P/N 38899 - PR7 - A01) after replacing the following parts:
NOTE:
. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refriqer-ant orls.
. lmmediately after using the oil, replace the cap on the container and seal ittoavoid moisture absorption,. Do not spill the refrigerant oil on the car; it may damage the paint; if the re{rigerant oil contacts the paint, wash itoff immediately.
Condenser ..................... 25 m/ (5/6 fl.oz, 0.9 lmp.oz)
Evaporator ................. ilo mf 17 113fl.oz,1.4 lmp.oz)
Line or hose 10 ml (1/3 fl.oz. o.il lmp'ozl
Receiver/Dryer .....,.,,...., 10 m{ l1l3 tl.oz, 0.4 lmp.ozl
Leakage repair .............. 25 mf (5/6 fl.oz, 0.9 lmp.ozl
Compressor For compressor .eplaco-
m€nt, subtract the volumo of oil drained from tho
removed compressor trom 140 ml 11 213 ll.oz, 1,9
imp.ozl, and drain the calculalgd volume of oil from
tho new compressor: 140 mf 11 213 ll. oz, 1.9
imp.ozl- Volume ot removod compressor = Volume
to drain from n€w compressor.
NOTE: Even if no oil is drained from the removed
compiessor, don't drain more than 50 ml 11 213
fl.oz, 1.8 lmp .oz) from the new comDressor.
O Dischargo hose to the compresso. (6 x 1.0 mml .............................. 9.8 N.m {1.0 kgt.m, 7.2 lbf.ft)(, Discharge hosa to ths condenser (6 x 1.0 mm) . 9.8 N.m {1.0 kgf.m, j.Z lbl.ftl@ Condenser pipe to tho condenser (6 x 1.0 mml 9.8 N.m n.O kaf.m,t-2tbl.ftl
@ Condenser pipe to the receiver/dryer (6 x 1.0 mm) ......................... 9.8 N.m (1.0 katm,7.2 lbf.ft)@ Receiver pipe A to tho receiver/dryer 16 x 1.0 mm) ......................... 9.8 N.m (1.0 kttm. 7.2 lbt.ft)@ Receiver pipe A to th6 receiver pipe B ......................................
O Receiver pipe B to the receiver pipe C .............................................. 13 N.m {1.3 kgt.m. 9.4 lbt'ft)
13 N.m {1.3 kgf.m.9.4 lbf'ft)@ Receiver pipe C to the evaporator (6 x 1.0 mm) 9.8 N.m {1.0 kgf.m , j.Zlbl.ftl
@Suaion pip€ B to the evaporator {6x 1.0 mm) ................ ................ 9.8 N.m tt.O t!f.-, r.Z tUt tt}@ Sustion pipe A to the suction pipe B .................. 3t N.m (3.2 klnm,23 lbf.ft)(, Suction hose lo the suction pipe A ................ ...... 31 N.m (3.2 kgf.m, 23 tbf.ftl
OA Suction hose to the compressor {5x 1.0 mm} ................ ................. 9.8 N.m 11.0 kgt.m,7.2 lbf.ft)
ET
22-21

A/C System Service
Recovery
Onlv use service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Expo3ute to air conditioner rcfrigelant rnd
lubricant vapor or mist can irritatc oyo!, no3o and
throat. Avoid bresthing the lir condhionot rofrigorlnt
and lubricant vapor or misl.
lf accidental system discharge occuts, ventilate work
area before resuming service.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
comoressed air.
!!@ some mixturos ot Eir and R'134. hsvc
bsen shown to be combu3tible st elavllcd prs33urc3
and can result in fire or oxplosion cau3ing iniurY or
property damage, Nsvor u36 comprg3Sod lir to P|'3turl
test R-134a servic€ equipmont o. vohiclc rir condhioncr
3ystems.
Additional health and safety information may be
obtained from the refrigerant and lubricant manufac-
rures.
'1. Connect a R-134a refrigerant Recovery/Recycling/
Charging System to the car, 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
comoleted.
NOTE: Be sure to install the same amount of new
refrigerant oil back into the A/C system befote
charging.
R.cov.rylR.cycling/Ch.rging sy.t m.
Pf,ESSUFE
22-22

Pressure Test Chart
NOTE: Performance Test on page 22-24.
TEST RESULTSRELATED SYMPTOMSPROAABLE CAUSEREMEDYDischsrge(high) pressureabnormallynrgn
AftEr stopping compressor, pressuredrops to about 200 kPa (2.0 kof/cmr. 28psi) quickly, and then falls gr;dua y.
Air in systemRecover, evacuate and recharqowith sDecified amount. -
Evacuation: see Daqe 22-38Charoino: se6 D;op--2?-?qNo bubbles in sight g16ss when con-denser is cooled bv water.E-\cessive refrigerant in sys-Recover, evacuate and recharqewith specitied amount. -
Reduced or no air flow through con-oenser.Clogged condenser orradiato. finsCondenser o. radiator fannot working properly
CleanCheck voltage and fan rpmunecK lan ofeclton
Line to condenser is excessivelv hot.Restricted flow of refriger-ant In syslem. Restricted lines
Discharge pres-su re abnormal-Excossive bubbles in sight glass;condenser is not hot.Insuff icient refrigerant insyslemCheck for leakCharge systemHigh and low pressures are balancedsoon after stopping compressor. Lowside is higher than normal,
Faulty compressor dis-cnarge vaNsFaulty compressor seal
Replace the compressor.
Outlet of expansion vslve is not frost-ed, low pressure gauge indicates vacu-um,
. Faulty expansion valve. Moisture in sysiem. Replace. Recover, evacuate and recharoewith specified amount. -
Suction (lowlpressureabnormally low
Excessive bubbles in sight glass;conqenser rs not hot_Insuff icient ref rigerantReoair the leaks.Reaover, evacuate and recharoewith sDecifisd amount. -
Charqe as required.Expansion valve is not trosted and lowpressur€ line is not cold. Low pressuregauge Inorcates vacuum.
Frozen expansion valveFaulty expansion valveReplace the expansion valve.
Discharge temperaturg is low and theair flow from vents is restricted.Froren evaporatorRun the tan with comoressor oftthen check Ay'C thermostat.Expansion valve is frost€d.Clogged expansion valveCl€an or replace.Receiver/dryer outlet is cool and inletisrryarm (should be warm during oper-Clogged r€ceiver/dry€rReplace
Suction pres-su re abnormal-ly high
Low pressure hose and check joint arecooler than the temDeraturo aroundevaDorator.
'
ffin"nsion u"lu" oD"n too
. Loose expansion capillary
Repair or replace.
Suction pressure is lowered when con-denser is cooled by water,Excessive refrigerant in sys-remRecover, evacuate and recharqewith sDecifi€d amount. -
High and low pressure are equalizedas soon as the compressor is stopped,and both gauges fluctuate while run-nrng.
Faultv oasketFaulty Figh pressure valveForeign particle stuck inhigh pressure valve
Replace the compressor.
Suction anddischarg€ pres-sufes aonor-mally high
Reduced air flow through condenser.. Clogged condenser orradiator fins. Condenser or radiator fannot working properly.
Clean condenser and radiatorCheck voltage and fan rpmCheck fan direcrion
No bubbles in sight glass when con-cl€nser is cooled bv water.Excessive refrigerant in sys-remRgcover, €vacuate and recharoewith sp€cified amount.Suction snddischarge pres-su r€ abnormal-
Low pressure hose and metal endafeas are cooler than evaDorator.Clogged or kinked tow pre€-sure nos€ pansFepair or replace.
Temperature around expansion valveis too low compared with that aroundrecerver/orver.
Clogged high pressure lineRepair or replace.
Refrig€rantleaksCompressor clutch is dirty.Compressor shaft seal leak-IngReplace the comDressor.
Compressor bolt(s) are dirty.Leaking around bolt(s)Tighten bolt(sl or replace com-pressor.Compressor gasket is wet with oil. IGasket leakingReplace the compressor.
22-23

A/G System Service
Performance Test
The performance test will help determine if the air con-
ditioner system is operating within specitications.
Only use service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a {R-134a) from the air conditioner system.
CAUTION: Exposure to air conditioner relrig€rant and
lubricant vapor ot mist can irritate eyes, nose and
throat. Avoid breathing the air conditioner rstrigerant
and lubricant vapor or mi3t.
It accidental system discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
comPressed atr.
!@ some mixtures ot air and R'1344 hrv6
been shown to be combustibls at elovatod prsssurel
and can result in firg or explosion causing iniury 01
property damage. Ngvor usg compregsed ail to prossuro
t€st R-134a ssrvice equipment or vohicl€ air conditioner
syst€ms.
Additional health and safety information may be
obtained from the refrigerant and lubricant manufactur-
ers.
1. Connect a R-134a refrigerant Recovery/Recycling/
Charging System to the car, as shown, iollowing
the equipment manufacturer's instructions.
2. Insert a thermometer in the center vent outlet.
Determine the relative humidity and air temperature
by calling the local weather information line,
3. Test conditions:
. Avoid direct sunlight.
. Open hood.
. Open front doors
. Set the temperature control lever to MAX COOL,
the mode control switch on VENT and the recir-
culation control switch on RECIRCULATE.
. Slide the heater fan switch on MAX
. Run the engine at 1,500 rPm
. No driver or passengers in vehicle.
4. After running the air conditioning for 10 minutes
under the above test conditions. read the delivery
temperature from the thermometer in the dash vent
and the high and low system pressure from the A,/C
gauges.
Rocov.rylB.cycling/Ch!lging SFtrm.
PRESSURELOW
22-24

To complete the chans:
. Mark the delivery temperaiure along th€ venical line.
o Mark the intake temperature (ambient air temperature) 8long the bottom line.
o Drsw a line strsight up from the air temperature to the humidity.
. Mark I point one line above and one line below the humidity l6vel (10 % above and 10 % below the humidity
l6vsl).
. From each point, drawa horizontal line across the delivery temparaturs.
. The delivery temperature should fall between the two lines,
. Complete the low side pressure test and high side pressur€ test in the same way.
o Any measurements outside the line may indicate the need for further inspection.
kp.lksf/cm')lpril29q)(301
Ii(t0l
2stx't25)t360l
at%
30%kprlkgflclrfllpril2qx)t20lt2q)l
15{Xt{15112r0t
9BOt10lt1()l
500ts)171!
T'EUVERYPRESSUNE
OEUVERYPRESSURE
86t30)
71l25l
68120,
59t15l
50(101
11ts)
,o0
{4)tsTl
3q,{3tI€I
ax)l2lt28t
100t1ln4lINTAKEPRESSUBE
DEUVERYTEMPEMTURE
77 6 95 104 "F
{25t t30t (35} laltl fc}
T-
INTAKE TEMPERATURE
22-25

Evaporator
Replacement
CATION:
. All SRS eloctrical wiring harnesses are coverod with
yollow in3ulation.
. B€tore disconnocting 8ny part of tho SRS wire har-
nsss, conngqt th€ 3hort connestor{sl.
. Roplaca ths entire aftected SRS harness a$embly if
it has an op€n circuit or damaged wiring.
lcove.ed with yellow insulation)
Recover the refrigerant with a Recovery/Recycling/
Charging System lsee page 22-22]-.
Femove the bolts, and disconnect the receiver line
and the suction line from the evaporator.
NOTE: Plug or cap the lines immediately after dis-
connecting to avoid moisture and dust contamina-
tion into the svstem.
2.
L
6x1.0mm9.8 N.m {1.019f.m,1.2 tbl.ttl
SUCTION LINE
RECEIVEB LINE
3.Remove the glove box (see section 20).
Remove the four bolts and the glove box frame.
Disconnect the connector from the Ay'C thermostat,
and remove the wire harness clips from the evapo-
rator.
Remove the four self-tapping screws, mounting bolt
and the mounting nut.
Disconnect the drain hose, and remove the evapo-
rator.
1.
6x1.0mmAPORATOR9.8Nm{1.0kg{.m,7.2 tbtft)
a
a
8. Install in the reverse order of removal. and:
it you're installing a new evaporator, add refrig-
erant oil (ND-OIL 8: P/N 38899 - PR7 - A01) (see
page 22-2'll.
replace the O-rings with new ones at each fitting.
and apply a thin coat of refrigerant oil (ND-OlL 8:
P/N 38899 - PR7 - A01l before installing them.
NOTE: Be sure to use the right o-rings for HFC-
134a {R-134a} to avoid leakage.
apply sealant to the grommets.
make sure that there is no air leakage.
charge the system (see page 22-39) and test its
performance (see page 22-241.
22-26

Overhaul
L Pull out the Ay'C thermostat sensor from the evapo-rator fins.
2. Remove the self-tapping screws and clamps fromthe housing.
3. Carefully separate the housings and remove theevaporator.
4. lf necessary, remove the expansion valve.
NOTE: When loosening the expansion valve nuts.use a second wrench to hold the expansion valve orevaporator pipe. Otherwise, they can be damaged.
Assemble in the reverse order of disassembly, and:
. feplace the O-rings with new ones at each fitting,and apply a thin coat of refrigerant oil (ND-OIL 8:P/N 38899 - PR7 - A01) before installing them.NOTE: Be sure to use the right O-rings for HFC-134a {R-134a) to avoid leakage.. install the expansion valve capillary tube withthe capillary tube in contact with the suction linedi.ectly, and wrap it with tape.. reinstall the Ay'C thermostat sensor to its originallocation.
A/C THERMOSTATTest. page 22-19
8 N.m (0.8 kgf'm, 6 lbf.ftl
CAPILLARY TUBE
5.
EVAPOAATORblow dirt out of finswith compressed air.
16 N,m 11.6 kgl.m,12 tbt.ttl
24 N.m (2.i1 kg{.m,17 rbt.ftl
EXPANSION VALVE
TAPEReplace.Make sure there is no foreign matter stuck betweenthe capillary tube and outlet line.
6 th fin trom inlet 3id6
12015 mm14.72 ! 0.2 inl
LOWER HOUSING
22-27

Gompressor
Description
This compressor is a Nippondenso piston type compressor for HFC-134a (R-'|34a). A revolving inclined disc drives the sur-
rounding 10 reciprocating prstons. As the inclined disc revolves. it pushes the pistons, protected by a ceramic shoe, thus
compressing the ref rigerant
/alo
22-28
?-*:-=3