1999 HONDA CR-V Ac lines

Evaporator
Replacement
1.Recover the refrigerant with a recovery/recycling/
charging station (see page 22-59).
Remove the battery.
Remove each bolt, then disconnect the suction and
receiver lines from the evaporator. Plug or cap the
lines immediately after disconnecting them to avoid
moisture and dust contamination,
RECEIVER LINE
..
\
6x1.0mm9.8 N'm (1.0 kgf m,7.2 tbl.ttl
Remove the glove box (see section 20).
Remove the self-tapping screw and the passenger's
dashboard lower cover, then remove the bolts and
the glove box frame together with the knee bolster.
GLOVE BOX FRAME
KNEE
22-44
6. Disconnect the connector from the evaoorator tem-
oerature sensor. and remove the wire harness from
the evaporator. Remove the self-tapping screws, the
mounting bolt and the mounting nut. Disconnect
the drain hose, then remove the evaporator.
5xl,0mm9.8 N.m {1.0
II
I
Io
kgf.m, 7.2 lbf.ftl
, -l: "
7.
EVAPORATOR
6x1.0mm9.8 N.m (1.0 kgtm,7.2lbf.ftl
Install in the reverse order of removal, and note of
these items.
. lf you're installing a new evaporator, add refrig-
erant oil (SP.10) (see page 22-541.
Replace the O-rings with new ones at each fit-
ting, and apply a thin coat of refrigerant oil
before installing them. Be su.e to use the right
O-rings for HFC-134a (R-134alto avoid leakage.
Apply sealant to the grommets.
Make sure that there is no air Ieakage.
Charge the system (see page 22-6'll, and test its
performance (see page 22-56]-,
a
a
a
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4. Disconnect the heater hoses from the heater unit.
Engine coolant will run out when the hoses are dis-
connected; drain in into a clean drip pan.
CAUTION: Engino coolant will damage p8int. Ouickly
rinse any spill€d engine coolant Itom painted sur-
faces.
HEATER HOSEIOUTLET SIDE)
Remove the mounting nut from the heater unit.
Take care not to damage or bend the fuel lines, the
brake lines. etc.
CLAMPS
13 N.m 11.3 kg{.m,9.4 lbtftl
22-51
7.
ll.
Remove the dashboard (see section 20).
Remove the evaporator (see page 22-48).
Disconnect the connectors from the mode control
motor and the air mix control motor, and remove the
wire harness clips and wire harness from the heater
unit. Remove the clip from the heater duct, then
remove the mounting nuts and the heater unit
6x1.0mm9,8 N.m (1.0 kgt m,7.2lblft)
qInstall in the reverse order of removal. Make note of
the following items.
a
a
a
a
Apply sealant to the grommets.
Do not interchange the inlet and outlet heater
hoses. Make sure that the clamps are secure.
Refill the cooling system with engine coolant
{see section 10).
Adiust the heater valve cable (see page 22-53).
Make sure that there is no air leakage.
HEATER UNIT
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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
resutr.
*KEIHIN SP-10:
. P/N 38897 - Pl3 - A01AH: 120 m{ (4 fl.oz, il.2 lmp.oz)
. P/N 38899 - Pl3 - A01: 40 mf 11113tl.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 refrigerant and lubricant vapor or misl can irritats eyes, nose and throat. Avoid
breathing the air conditioner refrigerant and lubricant vapor or mist,
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
air.
E@ Some mixtures of air and R-13,1a have been shown to be combustible at elevat€d pressures and can result
in fire or explosion causing iniury or property damage. Never use complessed air to pressure test R-l3,[a service equip-
ment or vehicle air conditioner 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 parts.
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 or loosening a fitting, use a second wrench to support the matching fitting.
5. When discharging the system, use a R l34a refrigerant recovery/recycling/charging station; don't release refrigerant
into the atmosphere.
6. Add refrigerant oil after replacing the following parts.
Note these items when handling refrigerant oil:
o 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 painu if the refrigerant oil contacts the paint, wash
it off immediately.
Condenser . 25 ml (5/6 tl.oz, 0.9 lmp.oz)
Evaporator.,................................40 m/ 11 113ll.oz,l.4 lmp.ozl
Line or hose ........... 10 ml (1/3 fl.oz, 0.4 lmp.oz)
Receiver/Dryer....... 10 ml (1/3 fl.oz, 0.4 lmp.oz)
Leakage repair............................ 25 m/ (5/6 ll.oz, 0.9 lmp.oz)
Compressor.......,..., For compressor replacement, subtract the volumg ol oil drained from the removed
compressor from 130 m{ (4 113 tl.oz, 1,6lmp.ozl, and drain the calculatsd volume of
oif from the now comprossor: 130 ml (,1 113 tl,oz, 1.6lmp'ozl - Volume of removed
compressor = Volume to drain from new compressor.
NOTE: Even if no oil is drained trom the removed compressor, don't drain more than
50mt 11 213ll,oz,1.8 lmp.oz) from the newcompressor.
22-54I
rso m r rr:0.o., r.s r-o.o.t
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5. To comDlete the charts:
. Markthe delivery temperature along the vertical line'
. Markthe intake temperature {ambient air temperature) along the bottom line'
. Draw a line straight up from the air temperature to the humidity'
. Mark a point 10% above and 10% below the humidity level'
a From each point, draw a horizontal line across the delivery temperature'
. The deliverv temperature should fall between the two lines'
. Complete the low-side pressure test and high-side pressure test in the same way'
. Anv measurements outside the line may indicate the need for further inspection
kPa{kst/cm')Ipsil
29r,0t30tl,a0l
2500(251
t3601
2000 ll20l I kp.t28ol | {ksf/cmz} "F
I lcsil Pcl1s00'l ,l0o I 85 -l
{15} | (4} | (301
r21or I t57l I I
ttl980 j 3oo -.J "r1 Irlol {31 I l25l Ir14ol r13l I ILI200 -l 68 Jt2) | (2ot Ir28r I II100 -.1 ss l
TNTAKE lli' I
(15r
IPRESSURE ] |50 -l
,to,
IDELIVERY ITEMPEBATURE .t :.] _rsl -ll
80v.
HUMIDITYLEVEI-
HUMIOITYLEVEL
HUMIDITYLEVEL
80vo
DELIVERYPRESSURE
fl6g j7 * 95 104
t2o) l25l (30) (351 (ro)fct
INTAKE TEMPERATURE
22-57
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A/C System Service
Pressure Test Chart
NOTE: Performance Test is on page 22-56.
Test resultsRelatad symptomsPrcbable caus€Remody
Discharge (high)pressure 6bnormallyhagh
After stopping compressor, pressuredrops to about 200 kPa 12.0 kgtlcm,,28 psi) quickly, and then lalls gradualty.
Air in systemDischarge, evacuate, and rechargewith specified amount.Evacuation: see page 22-60Charging: see page 22-61No bubbles in sight glass whencondenser is cooled by waterExcessive refrigerant in systemDischarge, evacuate, and rechargewith specilied amount.Reduced or no air flow throughcondenser. Clogged condenser or radia-tor fins. Condenser or radiator fannot wo.king properly
CleanCheck voltage and fan rpm.Check fan direction.
Line to condensor is excossivelv hot.Restricted flow of relrigerant insy$emFestricted lines
Discharge pressureabnormally lowExcessive bubbles in sight glass;condenser is not hot.Insufficient retrigerant inCheck for leak.Charge system.High and low pressures are balancedsoon after stopping compressor. Lowside is higher than normal.
. Faulty compressor discharge
. Faulty compressor seal
Replace the comprossor.
Outlet ot expansion valve is notfrosted, low-pressure gauge indicates
' Faulty expansion valve. Moisture in system. Replace. Discharge, evacuate, andrecharge with specified amount.Suction {low) pros,sure abnormallyExcessive bubbles in sight glass;condenser is not hot.Insufficiont relrigerant inRepair the leaks.Discharge, evacuate, andrecharge with specified amount.Charge as r€quired.Expansion valve is not frosted, andlow-pressure line is not cold. Low-pressure gauge indicates vacuum.
' Frozen expansion valvelMoisture in system). Faulty expansion valve
. Discharge, evacuate, andrecharge with specitied amount.. Replace th€ expansion valve.Discharge temperature is low, and theair llow trom vents is restricted.Frozen evaporatorRun the fan with compressor off,then check evaporator tempera,ture sensor.Expansion valve is frosted.Clogged expansion valveClean or replace.Feceiver/dryer outlet is cool, and inlotrs w6rm (should be warm duringoperation).
Clogged receiver/dryerReplace
Suction pressureabnormally highLow-pressure hose and check joint arecooler than tho temperature aroundevaporator.
. Expansion valve open too long. Loose expansion capillarytube
Repair or roplace.
Suction pressure is lowored whencondenser is cooled by water.Excessive refrigerant in systemDischarge, evacuate, and rechargewath specified amount.High and low-pressure are equalizedas soon as tho compressor is stopped,and both gauges tluctuate whilerunning.
Faulty gasketFaulty high-pressure valveForeign panicle stuck in high-
Replace the compressor.
Slction and dis,charge pressutesabnormally high
Reduced air flow through condens€r,. Clogged condenser orradiator tins. Condenser or radiator fannot working properly
CleanCheck voltage and fan rpm.Check Ian direction.
No bubbles in sight glass whencondenser is cooled by walerExcessive refrigerant jn systemDischarge, evacuate, and rechargewith specified amount.Suction and dis-charge pressureabnormally low
Low-pressure hose and motalendareas are cooterlhan evaporator.Clogged or kinked low-pressure hose pansRepair or replace.
Temperature around expansion valvers too low compared with that aroundClogged high-pressure lineRepair or replace.
Refrigerant leaksCompressor clutch is diny.Compressor shaft seal leakingReplace the compressor.Compressor boltls) are dirty.Leaking around bolt(s)Tighton bolt{s) or replacecompressor.Compressor gasket is wet with oil.Gasket leakingReplace the compressor,
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Compressor
Replacement
lf the compressor is marginally operable. run the
engine at idie 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 22-59).
Disconnect the condenser fan connector. Remove
the compressor clutch connector and the wire har-
ness clip from the condenser fan shroud, then dis-
connect the compressor clutch connector. Remove
the mounting bolts and the condenser fan shroud,
CONDENSER FANCONNECTOR
6x1.0mm7 N.m 10.7 kg{.m, 5 lbl.ftl
'L
2.
5. Remove 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 contamination,
6x1.0mm9.8 N.m 11.0 kgf.m,7.2 lbf.ft)
DISCHARGE LINE
Remove the power steering pump belt (see section
17t.
Loosen the pivot bolt of the idler pulley bracket and
the adiusting bolt, then remove the Ay'C compressor
belt from the pulleys. lf necessary, remove themounting bolts from the left front mount, thenremove the A,/C compressor belt through the gap
between the bodv and the left front mount.
6.
7.
PIVOT BOLT10 x 1.25 mmAIUUSTING 4,t N.m (4.5 kgf.m, 33 tbf.ftlt€FTFRONTMOUltlT
10x 1.25 mm COMPRESSOR/t4 N.m (4.5 kgl.m,33 lbtftl BELI
LINE
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Gondenser
't.
Replacement
Recover the refrigerant with a recovery/recycling/
charging ststion (see page 22-59)
Remove the front grille (see section 20).
Remove the coolant reservoii, but do not discon-
nect the reservoir hose Jrom the coolant reservoir
and the radiator.
Remove the bolts and the suction line bracket as
shown. Remove the bolts and the upper mount
brsckets from the radiator.
UPPER MOUNTBRACKETS
Remove each bolt, then disconnect the discharge
and condenser lines from the condenser, Plug or
cap the lines immediately after disconnecting them
to avoid moisture and dust contamination.
6x1.0mm9.8 N.m 11,0 kgf.m, 7.2 lbfttl
t\,l/
ait- -:
i..
6x1.0mm
6xl.0mm9,8 N.m 11.0 kgf'm' 7.2lbf'ft)
22-70
DISCHARGE LINE
CONDENS€R LINE
6. Remove the mounting bolts, then remove the con-
denser by lifting it up as shown. Be careful not to
damage the radiator and condenser fins when
removing the condenser.
Install in the reverse order of removal. Make note of
the following items.
. lf you're installing a new condenser, add refriger-
ant oil (sP-10) (see page 22-54]..
o Replace the O-rings with new ones at each fit-
ting, and apply a thin coat of refrigerant oil
before installing them. Be sure to use the right
O-rings for HFC-134a (R-134a) to avoid leakage.
. Be careful not to damage the radiator and con-
denser fins when installing the condenser.
. Be sure to install the lower mount cushions of
condenser securely into the holes,
. Charge the system (see page 22-61), and test its
performance (see page 22-56).
7.
1,0 mm
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