1996 HONDA CIVIC rad fan

22. Install the shift cable end on the control lever, and
install the shift cable on the shift cable bracket'
CAUTION: Take care not to bend the shift cable'
23. lnstall the clip in the direction shown.
LOCKNUT
SHIFI CABLE 29 N m {3.0 kg{ m, 22lblftl
SHIFT CABLEERACKET
WASHERIPLASTIC)
CONTROL LEVER
24, Connect the solenoid harness connector. the drive
pulley speed sensor connector. and the ground
cable terminals.
6x1.0mm12 N.m {1.2 kgf.m.8,7 rbtft)
GROUND CABLETERMINAL 6x1.0mm
GROUNDTERMINAL
12 N.m {1.2 kgf'm,8.7lbtfrl
DRIVE PULLEYSPEED SENSORCONNECTOR
SOLENOID HARNESS
CONNECTOR
25. Connect the starter motor cable on the starter motor.
and install the cable holder.
NOTE: When installing the staner motor cable. make
sure that the crimped side of the ring terminal is
facing out (see section 23).
STARTEB
BMOUNTING NUT
9 N.m (0.9 kgf m,7 lbf ft)
26. Install all removed connectors and clamps'
27. Install the distributor.
28. Install the intake air duct and air cleaner housing
29.
assemDly.
Refill the transmission with the recommended
Genuine Honda CVT Fluid (see page 14-2991
CAUTION: While filling the CvT Fluid, bs surs not io
allow dust and other fotoign particles to entor into
the transmission.
Connect the battery positive (+) terminal first, then
the negative (-l terminal to the battery'
Check the ignition timing (see section 23).
Start the engine. Set the parking brake, and shift the
transmission through all gears three times Check
shift cable adjustment (see page 14-355).
Check the front wheel alignment (see section 18)
Let the engine reach operating temperature (the
radiator fan comes on) with the transmission in lXl
or E position, then turn it off and check fluid level'
Perform the start clutch calibration procedure on
page 14-293.
Road test as described on pages 14-296 and 14-297
30.
31.
34.
36.
STARTER MOTOR
14-351

lllustrated Index
'96 - 98 Models
SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS
section {24) before performing repairs or service.
BLOWER UNITReplacement, page 21-37Overhaul, page 21-38
HEATER UNITBeplacement, page 21-39Overhaul, page 21-41BLOWERRESISTOBTest,
CONTROL MOTORTest, page 21-48Replacement, page 21'48
a/c swtTcH{wirh A/c)
MOO€MOTORTest, page 21 47Replacement, page 21'47
AIR MIX CONTROL CABLEAdjustment, page 2'1-44Replacement, page 21'43
HEATER FANswtTcHTest, page 2l'49
MODEHEATER CONTBOLPANELswrTcHEsTest, page 21 50Rgplacement, page 2'l-42Overhaul, page 21-43
TEMPERATURE CONTROLLEVERAdiustment, page 21 44
Detroster-aqtivated A/C System
Turning the defroster on activates the A,/C and sets the air flow mode to FRESH. lt is possible to turn the A,/C off or to
change the air flow to RECIRCULATE by pressing the A/C bunon or the FRESH/RECIRCULATE button.
21-2

Description
Outline
The air conditioner system removes heat from the passenger compartment by circulating refrigerant through the system
as shown below.
BLOWER FAN
EVAPORATOR(Absorption of heati
EOUALIZING TUBE(Meters pressure andimproves the expansionvalve reaction time)
into the evaporator)CAPILLATY TUBE SENSING BULB
lControls the temPerature of the
ref rigerant leaving the evaporator
by metering the expansion valve)
/\
THERMOSTAT
A/C PRESSURE SWITCH
When the refrigerant is below
200 kPa (2.0 kgtcm',28 Psi)or above 3,200 kPa 132 kgflcm',
455 psi), the Ay'C pressure
switch opens the circuit to
the A,/C switch and stops the
EXPANSION VALVE(Meters the requiredamount of refrigerant
airconditioning to Protect the
compressor.
RECEIVER/DRYER(Traps debris, andremoves morsturel
THERMAL PROTECTOR
{Opens the comPressorclutch circuit when the
compressor temPeraturebecomes too high)
RELIEF VALVE(Relieves pressure at the
compressor when thepressure is too high)
(Radiation of heat)
I
f-r--; I
(Suction and comPression,
HIGH PRESSURE VAPOR
HtGH PRESSUBE LIOUID
LOW PRESSURE LIOUID
This car uses HFC-134a (R-134a) refrigerant which does not contain chlorofluorocarbons Pay attention to the following
service items:
. Do not mix refrigerants CFC-12 (R-12) and HFC-134a (R-134a)' They are not compatible'
. Useonlythe recommended polyalkyieneglycol (PAG) refrigerant oil designedforthe R-134a compressor (SANDEN: SP-
10; DENSO: ND_OIL8). Intermixing ihe re-commended (pAG) refrigerant oil with any other refrigerant oil will result in
compressor failure.
. All A,,ic system parts {compressor, discharge line, suction line, evaporator, condenser, receiver/dryer, expansion valve'
O-rings for joints) have to be proper for refrigerant R- 134a Do not confuse with R-l2 parts'
. Use a halogen gas leak detector designed for refrigerant R-134a
. R-12 and R-134a refrigerant servacing 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 systems'
. Always recover the refrigerant R-134a with an approved recovery/recycling/charging station before disconnecting any
A,/C fitting.
S]
22-5

A/C System Service
Pressure Test Chart
NOTE: Performance Test is on page 22-24,
Test resultsRelated symptomsProbabl€ causeRemedy
Discharge (high)
pressure aDnor-
mally high
After stopping compressor. pres-
sure drops to about 200 kPa
{2.0 kgflcm,,28 psi) quickly, and
then falls gradually.
Air in systemRecover, evacuate, and
recharge with specified amount.
Evacuation: see page 22-45
Charging: see page 22-46
Reduced or no air flow through
condenser
. Clogged condenser fins. Condenser fan not work-
ing properly
Clean.
Check voltage and fan rpm.
Check fan direction.
Line to condenser is excessively
hot.
Restricted flow of refriger-
ant in system
Restricted lines
Discharge pres-
sure abnormally
High and low pressures are bal-
anced soon after stopping compres-
sor, Low side is higher than normal.
. Faulty compressor dis-
charge valve. Faulty compressor seal
Replace the compressor.
Outlet of expansion valve is not
frosted, low pressure gauge indi-
cales vacuum.
. Faulty expansion valve. Moisture in system
. Replace,. Recover, evacuate, and
recharge with specified
amount.
Suction (low)
pressure abnor-
mally low
Expansion valve is not frosted, and
low oressure line is not cold. Low
pressure gauge indicates vacuum.
. Frozen expansion valve. Faulty expansion valve
ReDlace the exoansion valve.
Discharge temperature is low. and
the air flow from vents is restricted.
Frozen evaporatorRun the fan with compressor
off. then check A,/C thermostat.
Exoansion valve is frosted.Clogged expansion valveClean or replace.
Receiver/dryer outlet is cool, and
inlet is warm (should be warm
during operation).
Clogged receiver/dryerReplace.
Suction pres-
sure abnormally
hig h
Low pressure hose and check
joint are cooler than the tempera-
ture around evaporator.
. Expansion valve open too
long. Loose expansion capillary
tube
Repair or replace.
Suction oressure is lowered when
condenser is cooled bv water.
Excessive refrigerant in sys-
tem
Recover. evacuate, and
recharge with specified amount.
High and low pressure are equal-
ized as soon as the compressor is
stopped, and both gauges fluctu-
ate while running.
Faulty gasket
Faulty high pressure valve
Foreign particle stuck in
high pressure valve
Replace the compressor.
Suction and dis-
charge pres-
sures abnormally
h igh
Reduced air flow through con-
denser.
. Clogged condenser fins. Condenser fan not work-
ing properly
Clean condenser.
Check voltage and fan rpm.
Check fan direction.
Suction and dis-
charge pressure
abnormally low
Low pressure hose and metal end
areas are cooler than evaporator.
Clogged or kinked low pres-
sure hose parts
Repair or replace.
Temperature around expansion
valve is too low compared with
that around receiver/dryer.
Clogged high pressure lineRepair or replace.
Refrigerant leaksCompressor clutch is diny,Compressor shaft seal leakingReplace the compressor.
Compressor bolt{s) are diny.Leaking around bolt(s)Tighten bolt(s) or replace com-
pressor.
Compressor gasket is wet with oil.Gasket leakingReplace the compressor.
22-26

Relay and Control Unit Locations
Engine Compartment
UNDER.HOOD ABS
FUSE/RELAY BOX
CONDENSER FAN
RELAY
UNDER.HOODFUSE/RELAY BOX
MOTORRELAY
A/C COMPRESSORCLUTCH RELAY
RADIATORFAN RELAY
ELD UNIT
t:
tr
tr
uI Il I tl I
23-7

Connector ldentification and WireHarness Routing
Engine Compartment Wire Harness
conneqtor of
Terminal
Number of
CavitiesLocationConnects toNotes
c201
c202
c202
c203
c204
c205
c206
c207
c208
c209
c210
c210
c211
c212
c213
c214
c215
10
6
2
2
2
1
3
2
1
2
8
Left side of engine companment
Left side of engine companment
Left side of engine companment
Left side of engine compartment
Behind front bumper
Behind front bumper
Left side of engine compartment
Behind front bumper
Left side of engine compartment
Left side of engine companment
Behind front bumper
Behind front bumper
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Behind front bumper
Main wire harness (C308)
Main wire harness (C309)
Main wire harness {C309)Cruise actuator
Windshield washer motor
Rear window washer motor
Left front turn signal/parking lightFront fog light
Left headlight
Ay'C wire harness 1C751)Horn
HOrn
Radiator fan motor
Right headlight
Right front turn signal/parking lightMain wire harness (C355)
Washer level switch
Optional
'96 - 97
models'98 - 99
models
Canada'99 model
G201
G202
Right side of engine compartment
Left side of engine compartment
Body ground, via engine compartmentwire harness
Body ground, via engine compartmentwrre harness*1r With cruise control*2: Without cruise control
23-2A

Fuses
Under-hood Fuse/Relay Box
cgo1lTo condensor fan relayl
Gr02lTo blower motor r€layl
c903*: Not usod
NOTE; View from the backside of the under-hood fuse/relav box.
[To radi.lor tan rolayl
cto5[To main wir6 harne$ (C3521]
fto l/c comprdssor]
lclutch relay I
c905lTo main wire ha.ness (C353ll
DE
tr
tr
tr
r-1
IJ
r"l17LI
n51
IJ
r"l56
LI
r"l57IJ
23-62
ITo main w;re ha.ness (C351ll

(l'-
Fuse NumberAmpswire ColorComponent(s) or Circuitlsl Protect€d
4180APower distribution
4240AWHT/BLKTo ignition switch (BAT)
437.5 AWHT/REDCeiling light, data link connector, trunk light
4415 AWHT/BLKPGM-Fl main relay
Not used
4640AWHT/BLUPower window motors (via power window relay)
477.5 AWHT/BLUAudio unit, clock, TCM (CVT), ECM/PCM (VBU)
4830AWHTNo.33 (7.5 A) fuse, To combination light switch (headlight)
49Not used
5030AWHT/GRNRear window defogger (via rear window defogger relay)
cl20AWHT/GRNPower door lock control unit, moonroof motor
15 AWHT/GRNHorn system, brake lights, brake signal
10 AWHT/BLKHazard warning light, turn signal/hazard rclay
54404WHT/REDOption {+B)
5540ABLU,A/VHTBlower motor (via blower motor relay)
204WHTCondenser fan motor (via condenser fan relay)
REDl'lc compressor clutch (via IVC compressor clutch relay)
204BLVBEDRadiator fan motor (via radiator fan relay)
23-6