1998 HONDA CIVIC Dryer

PGM-FI System
Intake Air Temperature (lAT) Sensor ('96 - 97 Models)
The scan tool indicates Diagnostic Trouble code (DTC) P0111: A range/performance problem in the lntake AarTemperature (lAT) Sensor circuit.
The IAT sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the intakeair temperature increases as shown below.
RES|STAI{CE {tol
. 32 .. ro. tr. 2r, zaa r..l-20 o 20 /|o ao ao 100 rrotlcl
INTAIG AIR TEMPEMTURE
- The MIL hss beon reported on.- DTC P0111 is stored.- Or from Probable C.use List.
Problem verification:1. Turn the ignition switch OFF.2. Disconnect the IAT sensor 2Pconnector,3. Remove the IAT sensor.4. Reconnect the IAT sensor 2p
5. Leave the IAT sensor exposedto ambaent temperature,6. Turn the ignition switch oN fll).7. Check the IAT with the scantool.
Rsplscg the IAT sensor.
Check tho IAT sensor output:1. Warm the IAT sensor with ahair dryer-2. Check the IAT with the scantool.
Did the IAT rise 2"F (1.C) or morefrom the ambient temperature?Int€rmittont failu.e, system is OKat this time.
Replsce the IAT sensor.
11-124

Door and Side Moldings
Replacement (cont'dl
Door molding removal:
The following materials and tools are required to repairthe door moldings.
NOTE: Followthe manufacturer's instructions.
Materials: (Reference)
. Stripe remover
3M 08907
Stripe adhesive remover
3M 08908
Adhesive tape
3M Super Automotive Attachment Tape
Tools;
a Protective tape
. Knife or Cutter
. Sponge or Shop towel. Infrared dryer
. Film
. Putty knife
. Alcohol
CAUTION: Put on gloves to protect your hands,
Remove the door panel, and pull back the plastic
cover,
Apply protective tape on and around the molding.
3. Release the clips from inside of the door. Carefullvcut the adhesive tape with a knife or cutter whilepulling the edge of the molding away trom the dooras shown.
NOTE: Take care not to scratch or bend the mold-Ing.
1.
KNIFE
DOOR MOLDING
\
20-104
Door molding installation:
1. Glue the new adhesive tape to the moldings assnown.
[\\\l : Adhesive tape tocations60 mm4D: t2 t i^l
40 mm11.6 in)
Forward L
REAR DOOR
2Dl3Dl
CLIPHOLDER
100 mm(3.94 inl1,050 mm 141.34 inl
Forward !
DOOR MOLDING
DOOR MOLDING
5 mm {0.2 inl
ADHESIVE TAPEThickness: 1.2 mm 10.05 in)
Installthe clips on the molding.
Heat the bonding surface of the door and doormolding with an infrared dryer.
Door: 104 - 140"F (40 - 60.C)Molding: 68 - 86"F (20 - 30.C)
NOTE: Use care when heating to prevent deforma-tion of the molding.
Align the molding with the clip locations, and setthe molding. Lightly push on the molding until itsedge is fully seated on the adhesive tape.
NOTE: Do not spray water on the motding withinthe first 24 hours after installation.
Reassemble all removed pans.

lllustrated Index
A/C PRESSURE SWITCHWhen the refrigerant pressure is below 200 kPa {2 0 kg7cm',
28 psi) due to ;frigerant leakage or above 3200 kPa (32 kgf/cm''
455 psi) due to refrigerant blockage, the lVC pressure swrtch
SERVICE VALVE
{LOW.PRESSURE SIDE)
EVAPORATORReplacement, page 22-28
Overhaul, page 22 29
Beplacement, Page 22'44
opens lhe circuit to ihe AVC switch and stops the air condilioning
to protect the comPressor'
RECEIVER/DRYER
COMPRESSORSANDENIReplacement, Page 22 30
CIutch Inspection, Page 22 33
Thermal Protector Inspection, page 22 33
Clutch Overhaul, Page 22'34
Thermal Protector Replacement, page 22 36
Refief Vafve Replacemenl, page 22'36
DENSO:Replacement, Page 22-37
Clutch Inspection, Page 22-40
Clutch Overhaul, Page 22_41
Relief Valve Replacement, page 22-42
A/C THERMOSTATTest, page 22 21
22-3

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 Service Tips and Precautions
The air conditioner system uses HFC-134a (R-134a) refrigerant and polyalkyleneglycol (PAG) refrigerant oil*, which are not
compatible with CFC-12 (R-12) refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do
not attempt to use R-12 servicing equipmenU damage to the air conditioner system or your servicing equipment will result.*Sanden SP-10:
. P/N 38897 - P13 - A0lAH: 120 ml 14ll.oz, 4.2lmp.oz)
. P/N 38899 - P13 - A0l | 40 mf 11 1/3ll.oz,1.4 lmp'oz)
Use only service equipment that is U.L. listed and is certified to meet the requirements of SAE J2210 to remove R 134a
from the air conditioner system.
CAUTION: Exposure to air conditioner ref;ige;ant and lubricant vapol or mist can irritate syes, nose and throat, Avoid
breathing the air conditioner refrigerant and lubricant vapor or misl.
lf accidental system discharge occurs, ventilate work area before resuming service.
R-'134a service equipment or vehicle air conditioner systems should not be pressure tested or leak tested with compressed
ai.
!@@ some mixtures of air and R-t3ila have been shown to be combustible at elevated pressures and can result
in tire or explosion causing iniury or property damage. Never use compressed air lo pressure tesl R-134a service equip-
ment or vehicle 8ir conditioner systoms.
Additional health and safety information may be obtained from the refrigerant and Iubricant manufacturers.
L 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't
remove the caps or plugs until just before you reconnect each line.
3. Before connecting any hose or line, apply a few drops of refrigerant oilto the O-ring.
4, When tightening o. loosening a fitting, use a second wrench to support the matching fitting.
5. When discharging the system, use a R-134a refrigerant recovery/recycling/charging station; don't release refrigerant
into the atmosphere,
6. Add refrigerant oil 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 refriger-
ant 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 paint; if the refrigerant oil contacts the paint, wash
it off immediately.
Condenser .......2o ml (2/3 fl.oz, 0.7 lmp.ozl
Evaporator .,.,.,. i[5 m{ 11 213 tl.oz,1,6lmp.ozl
Line or hose ..... 10 mf (1/3 fl.oz, 0.4 lmp.ozl
Receiver/Dryer 10 m{ (1/3 fl.oz,0.'l lmp.ozl
Leakage repair 25 m{ (5/6 fl.oz, 0.9 lmp.ozl
Comptessor ... For compressor replacement. subtract the volume of oil drained trom the
removed compressor from A, and drain the calculated volume of oilfrom the new
compressor: A - Volume of removed compressor: Volume to drain from new
comoressor.
A: SANDEN 130 mf l/t 113 ll.oz, 4.6 lmp'ozl; DENSO 140 mf {4 213 ll'oz, 1.9
lmp.oz),
NOTE: Even if no oil is drained from the removed compressor, don't drain more
than S0 m{ 112Ell.oz,1.8 lmp.oz) fromthe new compressor.
REMOVED NEW
COMPRESSORCOMPRESSOR
*DENSO ND-OlL 8l
. P/N 38897 - PR7 - A01AH: 120 ml (4 fl.oz)
. P/N 38899 PR7-A01:40mf (1 1/3fl'oz)
rereW W0000
22-22
-0_!- -0_a
Tol l00l
| | lffi 1 onrrrutrc I
fi+-sAME
LEvEr...+jEf,voLUME
J
^

A/C System Torque Specifications
O Discharge hose to the compressor (6 x 1.0 mml ............... .. .... ...............' 9.8 N'm {1.0 kgf'm,7.2 lbf'ftl
@ Discharge hose to the condenser {6 x 1.0 mm1................... '... ...... . ......... 9.8 N'm 11.0 kgf'm, 7.2 lbf'ft}
O Condenser pipe to the condenser 16 x 1,0 mm)...............'. . . . ...........'..... 9.8 N'm (1.0 kgl'm, 7.2 lbt'ft)
@ Condensel pipe to the receivel/dryer (5 x 1.0 mml......... ..... . ... . '.......... 9.8 N'm (1.0 kgl'm, 7.2 lbt'ft)
O Receiver pipe A to the leceiver/dryer {6 x 1.0 mm)......... ... .......... .. . . .... 9.8 N'm 11.0 kgf'm. 7.2 lbl'ft)
@ Receiver pipe B to the receiver pipe A 13 N m (1.3 kgf'm, 9.'l lbf'ft)
O Receiver pipe C to the receiver pipe B 13 N m (1.3 kgf'm, 9.4 lbnftl
@ Receiver pipe C to the evaporator {6 x 1.0 mm) ....... 9.8 N'm (1.0 kgf'm, 7.2 lbtftl
O Suction pipe B to the evaporator (6 x 1.0 mml................ . .........'......'....... 9.8 N'm (1.0 kgf m, 7.2 lbf'ftl
e0 Suction pipe A to the suction pipe B ...'. . ...... . ... ...... 31 N'm (3.2 kgt'm, 23 lbf'ftl
O Suction hose to the suction pipe A... ............ . . '......... 31 N'm (3.2 kgl'm, 23 lbf'ft|
@ Suction hose to the compressor (6 x 1.0 mm)................... .. . ... .. ............ 9.8 N'm (1.0 kgf'm' 7.2 lbf'ft|
@@ Compressor to the compressor bracket (8 x 1.25 mm)... ..-........'.'......-.......24 N'm (2 'l kgf'm, 17 lbf ftl
@ Compressor bracket to the cytinder block (10 x 1.25 mml 44 N'm l'1.5 kgf'm, 33 lbf ftl
@ Compressor bracket to the left front engine mounl {12 x 1.25 mm}..... . . . . .. ................. ... ... 59 N'm (6.0 kgf'm, '|i} lbf ftl
22-23

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

A/C System Service
Evacuation
Use only service equipment that is U L.-listed and is cer-
tified to meet the requirements oJ SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system'
CAUTION: Exposure to air conditioner reftig€lant and
lubricant vapor or misi can irrhaie eyes. noso and throat'
Avoid breathing the ail condhioner lefrigelant and lubri
cant vapor or mist.
lf accidental system discharge occurs, ventilate work
area before resuming servace.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
comDressed air.
!!@@ some mixtures of air and R-13'[8 haYo boon
ffiiE-n to be "ombustible at elovatod pressurcs and can
result in fire or explosion causing iniury or propsrtY
damag€. Never uso complsssod air to pre3surs tost R-
1344 ssrvico equipment or vehicle air conditioner sy3-
tems,
Additional health and safety information may be obtained
from the refrigerant and lubricant manuJacturers'
When an A,/C System has been opened to the atmo-
sphere, such as during installation or repair, it must
be evacuated using a R-134a refrigerant recovery/
recycling/charging station. (lf the system has been
open for several days, the receiver/dryer should be
replaced, and the system should be evacuated for
several hours.)
Connect a R-134a refrigerant recovery/
recycling/charging station to the vehicle, as shown'
following the equipment manufacturer's instruc-
trons.
NOTE: lf low pressure does not reach more than 93 3
kPa (7OO mmHg,27.6 in.Hgl in 15 minutes, there is
probably a leak in the system Partially charge the
system, and check for leaks (see Leak Test)
1.
R6covory/Recyclin g/Chal9ing Station
22-45'