1994 HONDA INTEGRA Thermostat

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

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

Connector ldentification and Wire Harness Routing
Hoator Sub-harneEs A
Hoator Sub-hameEs B
Connoctor or
Terminal
Numb€r of
CavitiesLocationConn6cts toNotog
c671
c672
c673
c674
c675
c676
c677
'lo
2
4
4
14
Under right side ot dash
Under right side of dash
Under right side of dash
Behind glove box
Behind glove box
Behind glove box
Behind middle of dash
Main wire harness (C404)
Main wire harness (C4o3)
Blower motor
Blower resistor
Recirculation control motot
A/C thermostat
Heater sub-harness B (C681)
connoctor 01
T6rminal
Number of
CavitioELocationConnocts toNotos
c681
c682
c683
c684
14
I
6
14
Behind middle of dash
Middle ol floor
Behind middle of dash
Behind middle of dash
Heater sub-harness A (C677)
Mode control motor
Heater Jan switch
Heater conttol Panel
HEATER SUB-HARI{ESS B
23-46

Fan Controls
Fan Motor Test
1. Disconnect the 2-P connector from the fan motor.
2. Test the motot by connecting battery power to the
B terminal, and ground to the A terminal
3. lf the Jan motor fails to run smoothly, replace it.
NOTE: The illustration shows the radiator fan.
Engine Coolant Temperature (ECT)
Switch Test
NOTE: Bleed air from the cooling system atter install-
ing the engine coolant temperature (ECT) switch (see sec-
tion 1O).
1. Remove the ECT switch from the thermostat
housing.
2. Suspend the ECT switch in a container of coolant
as shown.
Heat the coolant and check engine coolanl tempera-
ture with a thermometer.
Check the continuity between the A and B terminals
according to the table:
Terminal
;;,".,"---\
B
Switch
Above 196 2O3"F
{91-95'C)o_-o
Below 181- 189oF
(83-87'C)
23-112