1996 HONDA CIVIC iat

Evaporator
1.
Replacement
4.
Move the temperature control to "HOl"
'96-98: Slide the temoerature control lever.'99-00: Turn the ignition switch ON (ll), then turn
the temperature contol knob. Turn the ignition
switch off.
Remove the battsry.
Rgcover the refrigerant with a rocovery/recycling/
charging station (see page 22-271.
Remove the bolts, then disconnect th6 suction 8nd
receiver lines from th6 evaoorator.
NOTE: Plug or cap the lines imm€diatoly after dis-
connecting them to avoid moisture and dust con-
tamination.
6xl.0mm9.8 n*ln ll.0 tg6m.7.2 lbt frl
RECEiVER UNE
Remove the glov6 box (see section 20).
Removo the self-tapping scr€w and the passeng€r's
dashboard lower cover. Removs the bolt. the nut
8nd the kn€e bolst6r, th6n r6mov6 th6 fiv6 bolts and
the glove box frame.
6.
srrcrrc u E
22-28
7. Disconnect the connector from th€ Ay'C thermostat,
and r€movs the wire harness from the ovaporator.
Remov6 tho four self-tapping screws, tho mounting
bolt and ths mounting nut. Disconnect th€ drain
hose, then remov€ th6 avagorator.
6 x l.0.nm9.8 l$m lt.o ldm, 7.2 bl.tt)
Install in the reverse order of removal. Make note of
th€ following items.
o lf you'r6 installing a new evaporator, add rofriger-
ANt OiI {SANDEN, SP-10 Or DENSO, ND-OIL 8)
lsas page 22-221.
. Replace the O-rings with now ones 8t 68ch titting,
and apply 8 thin coat of r€frlgersd oil before
installing them.
NOTE: Be sure to use the right O-rings for HFC-
134a (R-134a) to avoid loakago.
. Apply s€alant to tha grommets.
. Mske sure that ther€ is no air leakage.
. Chargs ths system {s€€ page 22-161, and tost its
performance (see pags 22-211.

Compressor (SANDENI
Replacement
1.lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioner
work for a few minutes. then shut the engine off.
Disconnect the negative cable from the battery.
Recover the refrigerant with a recovery/recycling/
charging station (see page 22-27l..
Remove the bolts, then disconnect the suction and
discharge lines from the compressor.
NOTE: Plug or cap the lines immediately after dis-
connecting them to avoid moisture and dust con-
tamination.
6xl.0mm
Remove the condenser (see page 22-44).
NOTE: Do not disconnect the discharge hose from
the condenser.
Remove the power steering pump belt (see section
17 t.
22-30
24 N.m l2.ia kgt.m, 17 lbf.ftl
7. Loosen the center nut of the idler pulley and the
adjusting bolt. then remove the A,/C compressor belt
from the pulleys. Remove the two mounting bolts
from the left front mount, then remove the ly'C com-pressor belt by passing it through the gap befiiveen
the bodv and the left front mount.
ADJUSTING BOLT
1.0 x 1.25 mmaa N.m 14.5 kgf,m, 33 bnft)
8. Remove the four mounting bolts and the compressor.
CENTER NUT
COMPRESSOR

9. lf necessary, remove the compressor bracket as fol-
lows.
. Remove the nut and the washer.
NOTE: When tightening the nut of the left front
mount, make sure the washer is set properly on
the left front engine mount as shown.
. Remove the four mounting bolts and the com-
pressor bracket.
12 x 1.25 rrirn59 N.m 16.0 kgt'm,43 tbf.ft)
COMPRESSORBRACKET
WASHER
1.0 x 1.25 mm44 N.m (i1.5 kg{.m, 33 lbl.ft)
LEFT FRONTMOUNT
10. lnstall in the reverse order of removal. Make note of
the following items.
. lf you're installing a new compressor, drain all
the refrigerant oil from the removed compressor,
and measure its volume. Subtract the volume of
drained oil from '130m? 14 1/3 tl'o2,4 6 lmp'oz);
the result is the amount of oil you should drain
from the new compressor (through the suction
fifting).
. Replace the O-rings with new ones at each fit-
ting, and apply a thin coat of refrigerant oil
before installing them
NOTE: Be sure to use the right O-rings for HFC-
134a (R-134a) to avoid leakage
. Use refrigerant oil (SP-10) for R-134a Sanden and
Hadsys spiral type compressors only'
o To avoid contamination, do not return the oil to
the container once dispensed, and never mix it
with other refrigerant oils.
. lmmediatelY after using the oil, replace the cap
on the container, and seal it to avoid moisture
absorption.
. Do not spill the refrigerant oil on the vehicle; it
may damage the painu if the refrigerant oil con-
tacts the paint, wash it off immediately
. Adjust the Ay'C compressor belt (see page 22-43)
and the power steering pump belt (see section 17)'
. Charge the system (see page 22-46), and test its
oerformance (see Page 22-241
22-31

Compressor (SANDENI
Thermal Protestor Replacement
1. Remove the bolt, the ground terminal and the hold-er. Disconnect the field coil connector. then removethe thermal Drotector.
7.{ N.m 10.75 ksf.m,5lbtfr)
/
SILICONE SEALANT
3. Install in the reverse order of removal.
GROUNDIERMINAL
HOI.I'ER
PNOTECTOR
Replace the thermal protector with a new one. andapply silicone sealant to the top of the thermal pro-
tector.
22-36
oo
Relief Valve Replacement
'1.Remove the relief valve and the O-ring.
NOTE:
. Do not let the compressor oil runout.. Make sure that no foreign matter enters the sys-tem,
RELIEFVALVE9.8 N.m {1.0 kgl.m,7.2 tbl.lrl
O.RINGReplace.
Clean the mating surfaces.
Replace the O-ring with a new one at the relief valve.and apply a thin coat of refrigerant oil beforeinstalling it.
NOTE:
. To avoid contamination. do not return the oil tothe container once dispensed, and never mix it
with other refrigerant oils.o lmmediately after using the oil, replace the capon the container, and seal it to avoid moistureabsorption.
. Do not spill the refrigerant oil on the vehicle; itmay damage the paint; if the refrigerant oil con-tacts the paint, wash it off immediately.
Install and tighten the relief valve.
Charge the system {see page 22-461, and test itsperformance 1se6 page 22-241.

Compressor (DENSO)
Replacement
1.lf the 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
Disconnect the negative cable from the battery'
Recover the refrigerant with a recovery/recycling/
charging station lsee page 22-271
Remove the each bolt, then disconnect the suction
and discharge lines from the compressor' Plug or
cap the lines immediately after disconnecting them
to avoid moisture and dust contaminatlon.
6 x '1.0 mm9.8 N.m (1.0 kgf m,7.2 lbfft)
Remove the condenser, but do not disconnect the dis-
charge hose from the condenser (see page 22-441'
Remove the power steering pump belt (see sectron
17]-.
7. Loosen the pivot bolt of the idler pulley bracket and
the adjusting bolt. then remove the A,/C compressor
belt from the pulleys. lf necessary, remove the mount-
ing bolts from the left front mount. then remove the
fuC compressor belt through the gap between the
bodv and the left front mount.
'10 x 1,25 mm4,0 N.m (,1.5 kgf'm. 33 lbt ftl
Disconnect the compressor clutch connector, then
remove the mounting bolts and the compressor'
PIVOT BOLT10 x 1.25 mm4,1 N.m (4.5 kgt'm,33 lbfft)
COMPRESSOR
24 N.m (2.4 kgf m, 17 lbf ftl
(cont'd)
22-37

Compressor (DENSOI
Replacement (cont'd)
9. Remove the bolts, the suction service valve and theO-ring from the compressor,
lf necessary, remove the compressor bracket as fol-lows.
. Remove the nut and the washer from the left frontmount. When tightening the nut to the left frontmount, make sure the washer is set p.operly onthe left front mount as shown.
a Remove the mounting bolts and the compressor
bracket.
12 x 1,25 rnm59 N.m 16.0 kgfrm,
10.
LEFT FRONTMOUNT€ rbf.fi)Roplace.
WASHEB
x 1.25 mm
2s.5 N.m {2.6 kgf.m. 18.8 tbtttl
4/r N.m {4.5 kgf.m, 33 lbt ft}
22-3A
1 1. Install in the reverse order of removal, and note thesertems:
lf you're installing a new compressor. drain all therefrigerant oil from the removed compressor. andmeasure its volume. Subtract the volume ofdrained oil from '140 ml (4 28 fl{,z, 4.9 lmpoz); theresult is the amount of oil you should drain fromthe new compressor (through the suction fifting).Replace the O-rings with new ones at each fining,and apply a thin coat of refrigerant oil beforeinstalling them. Be sure to use the right O,ringsfor HFC-134a (R-134a) to avoid leakage.
Use refrigerant oil {DENSO, ND-OtL8) for HFC-134aDENSO piston type compressors only.To avoid contamination, do not return the oil tothe container once dispensed, and never mix itwith other refrigerant oils.
lmmediately after using the oil, replace the capon the container, and seal it to avoid moisture
absorption.
Do not spill the refrigerant oil on the vehicle; itmay damage the paint; if the refrigerant oil con-tacts the paint, wash it off immediatelv.
Adjust the ly'C compressor belt (see page 22-43)and the power steering pump belt (see section 17).Charge the system (see page 22-46), and test itsperformance (see page 22-24!..

Condenser
Replacement
1.Recover the refrigerant with a recovery/recycling/
charging station lsee page 22-271.
Disconnect the condenser fan connector from theAy'C wire harness, then remove the A,/C wire harnessfrom the condenser fan shroud.
Remove the bolts, then disconnect the dischargeand condenser lines from the condenser.
NOTE: Plug or cap the lines immediately after dis-connecting them to avoid moisture and dust con-tamination,
6r1.0
6x1.0mmolscHARGE L|NE 9.8 N.m 11.0
9.8 N.m 11.0 kgl.m, 7.2 lbf.ftl
22-44
4. Remove the bolt from the suction hose bracket, andremove the two bolts and the upper mount bracket.Remove the condenser assembly by lifting it up.
NOTE: Be careful not to damage the condenser finswhen removing the condenser assembly.
UPPER MOUNT BRACKET
5. Install in the reverse order of removal. Make note ofthe following items.
. lf you're installing a new condenser, add refriger-ant oil (SANDEN, SP-10 or DENSO, ND-O|L 8)
\see page 22-22l.-
. Replace the O-rings with new ones at each fit-ting, and apply a thin coat of refrigerant oilbefo.e installing them.
NOTE; Be sure to use the right O-rings for HFC,134a (R-134a) to avoid leakage.o Be careful not to damage the condenser finswhen installing the condenser assembly.. Charge the system (see page 22-46), and test itsperformance (see page 22-24i.
6x1.0mm9,8 N.m 11.0 kg{.m, 7.2lbtft}
6x1.0mm9.8 N.m 11.0 kst m, 7.2 lbf.ftl

Troubleshooting
ll.
Tips and Precautions
Bef ore Troubleshooting
. Check applicable fuses in the appropriate fuse/relay
box.
. Check the battery for damage, state of charge, and
clean and tight connections.
. Check the alternator belt tension.
CAUTION:
. Do not quick-charge a battery unless the battery
ground cable has been disconneqted, otherwise you
will damage the alternator diodes.
. Do not attempt to crank the engine with the battery
ground cable loosely connecled or you will severely
damage the wiling,
Handling Connectois
. Make sure the connectors are clean and have no loose
wire terminals.
. Make sure multiple cavity connectors are packed with
grease (except watertight connectors)
. All connectors have push-down release type locks.
Some connectors have a clip on their side used to
attach them to a mount bracket on the body or on
another component. This clip has a pulltype lock.
Some mounted connectors cannot be disconnected
unless you first release the lock and remove the con-
nector from its mount bracket.
LOCKINGPAWL ONOTHERHALF OFCONNECTOR
Pull todrsengage
LOCKING TAB
BRACKET
Never try to disconnect connectors by pulling on
their wires; pull on the connector halves instead
Alwavs reinstall plastic covers.
Before connectang connectors,
nals are in place and not bent.
make sure the terml-
. Check for loose retainer and rubber seals.
RETAINER
The backs of some connectors are packed with
grease. Add grease if necessary. lf the grease is con-
taminated, replace it.
(cont'd)
23-3