2003 HONDA CIVIC Workshop Manual

Heating and Air Conditioning
Heater Valve Cable Adjustment
1. From underthe hood, open the cable clamp {A),
then disconnect the heater valve cable (B) from the
heater valve arm {C).
tFrom under the dash, disconnect the heater valve
cable housing from the cable clamp (A), and
disconnect the heater valve cable (B) from the air
mix control linkage {C).
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Set the temperature control dial on Max Cool with
the ignition switch ON (ll).
Attach the heater valve cable (B) to the air mix
control linkage (C) as shown above, then snap the
heater valve cable housing into the cable clamp (A).
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21-46
5, From under the hood, turn the heater valve arm {C)
to the fully closed position as shown, and hold it.
Attach the heater valve cable (B) to the heater valve
arm, and gently pull on the heater valve cable
housing to take up any slack, then install the heater
valve cable housing into the cable clamp (A).
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Compressor 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.
2. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the radio's
preset buttons.
3. Disconnect the negative cable from the battery.
4. Recover the refrigerant with a recovery/recycling/
charging station (see page 21-53).
5. Remove the alternator (see page 4-29).
6. Remove the Ay'C condenser fan assembly (see page
10-10).
7. Disconnectthe compressor clutch connector (A),
remove the bolts, then disconnect the suction line(B) and the discharge line (C)from the compressor.
Plug or cap the lines immediately after
disconnecting them to avoid moisture and dust
contamination.
6 x '1.0 mm9.8 N.m11.0 kgt.m,7.2 tbl.ttl
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8. Remove the mounting bolts and the compressor.
8 x 1.25 mm22 N.m 12.2 kgf.m.
9. Installthe compressor in the reverse order of
removal, and note these items:
. Before installing the new compressor, check for
metal or other contamination in the line. Replace
any contaminated parts.. lf you're installing a newcompressor, you must
calculate the amount of refrigerant oil to be
removed from it (see page 21-6).. Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them. Be sure to use the correct O-rings
for HFC-134a {R-134a) to avoid leakage,. Use refrigerant oil (KElHlN SP-'10) for HFC-134a
KEIHIN spiral type compressor only.. To avoid contaminatlon, do not return the oilto
the container once dispensed, and never mix it
with other refrigerant oils.. lmmediately after using the oil, reinstallthe 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. lf the refrlgerant oil
contacts the paint, wash it off immediately.. Charge the system (see page 21-55).. Do the engine control module (ECM) idle learn
procedure (see page 11-'139).. Enter the antitheft code for the radio, then enter
the customer's radio station presets.
21-47

Heating and Air Gonditioning
1.
Compressor Clutch Check
Check the armature plate for discoloration, peeling,
or other damage. lf there is damage, replace the
clutch set (see page 21-49),
Check the rotor pulley bearing play and drag by
rotating the rotor pulley by hand. Beplace the
clutch set with a new one if it is noisy or has
excessive play/drag (see page 21-49).
Measure the clearance between the rotor pulley (A)
and the armature plate (B) all the way around. lf the
clearance is not within specified limits, remove the
armature plate (see page 21-49) and add or remove
shims as needed to increase or decrease clearance.
Clearance: 0.510.15 mm {0.02010.006 in.)
NOTE: The shims are available in four thicknesses:
0.1 mm.0.2 mm,0.4 mm, and 0.5 mm.
21-48
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4. Release the field coil con nector f rom the holder,
then disconnect it. Check the thermal protector for
continuity. lf there is no continuity, replace the
thermal protector (see page 21-51).
NOTE: The thermal Drotector will have no
continuity above 252to270"F \122lo 132'C). When
the temperature drops below 241 to 219'F (116 to
104'C), the thermal protector will have continuity.
Check resistance of the field coil. lf resistance is not
within specifications, replace the field coil
(see page 21-49).
Field Coil Resistance: 3.05 3.35ohmsat68"F
t20"c)
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Compressor Clutch Overhaul
Special Tool Required
A,/C clutch holder, Robinair 10204. Kent-Moore J37872,
or Honda Tool and Equipment KMT-J33939,
commercially available
1. Remove the center nut (A) while holding the
armature plate with a commercially available A,/C
clutch holder (B).
17.6 N.m{1.8 kgf.m,13 tbt.ft)
Remove the armature plate (A) and shim(s) (B),
taking care not to lose the shim(s). lf the clutch
needs adjustment, increase or decrease the
number and thickness of shims as necessary, then
reinstallthe armature Dlate, and recheck its
clearance (see page 21-481.
NOTE: The shims are available in four thicknesses:
0.1 mm,0.2 mm,0.4 mm, and 0.5 mm.
9-=-g
3. lf you are replacing the field coil, remove the snap
ring (A) with snap ring pliers, then remove the rotor
pulley (B). Be careful not to damage the rotor pulley
or tne compressor.
4. Remove the bolt and holder (A). then disconnect
the field coil connector (B). Loosen the clamp screw(C) to iree the field coil wire. Remove the snap ring
{D)with snap ring pliers, then remove the field coil(E). Be careful not to damage the field coil or the
comoressor.
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7.4 N.m(0.75 kgf m,5 tbf.ft)---------------- ")
(cont'd)
21-49

Heating and Air Gonditioning
Compressor Clutch Overhaul (cont'd)
5. Reassemble the clutch in the reverse order of
disassembly, and note these items:
. Installthe field coil with the wire side facing
down, and align the boss on the field coil with the
hole in the compressor.. Clean the rotor pulley and compressor sliding
surfaces with contact cleaner or other
non-petroleum solvent..Install new snap rings, note the installation
direction, and make sure they are fully seated in
the groove.
. Make sure that the rotor pulley turns smoothly
after it's reassembled,. Route and clamp the wires properly or they can
be damaged by the rotor pulley.
21-50

Compressor Thermal Protector
Replacement
1. Remove the bolt, the ground terminal (A), and the
holder (B). Disconnect the field coil connector (C).
then remove the thermal protector (D).
Replace the thermal protector (A) with a new one,
and apply silicone sealant (B) to the bottom of the
thermal Drotector.
A
3. lnstall in the reverse order of removal.
7.4 N.m(0.75 kgf.m,5 rbf.ftl
Compressor Relief Valve
Replacement
2.
1.
4.
Recover the refrigerant with a recovery/recycling/
charging station (see page 21-53).
Remove the relief valve (A) and the O-ring (B). Plug
the opening to keep foreign mafter from entering
the system and the compressor oil from running
out.
A9,8 N.m(1.0 kgf m,7.2lbf.ft)
Clean the mating surfaces.
Install a new O-ring on the relief valve, and apply a
thin coat of refrigerant oil to the O-ring.
Remove the plug, and install and tighten the relief
valve.
Charge the system (see page 21-55).
21-51

Heating and Air Conditioning
Gondenser Replacement
1.
6x1.0mm9.8 N.m ('1.0 kgf.m,7.2lbf.ft)
Recover the refrigerant with a recovery/recycling/
charging station (see page 21-53).
Remove the front bumper {see page 20-85).
Remove the bolts, then disconnect the discharge
line (A) and the condenser line (B) from the
condenser. Plug or cap the lines immediately after
disconnecting them to avoid moisture and dust
conlamtnaflon.
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6x1.0mm9.8 N.m (1.0 kgt.m.7.2lbf.ft)
21-52
4, Remove the mounting bolts, then remove the
condenser by lifting it up. Be careful not to damage
the radiator or the condenser fins when removino
the condenser.
6 x '1.0 mm9.8 N.m ('1.0 kgf.m,7.2 tbl.ftl
5.lnstallthe condenser in the reverse order of
removal, and note these items.
. lf you're installing a newcondenser, add
refrigerant oil (KElHlN SP- 10) lsee page 21'6).. Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them. Be sure to use the correct O-rings
for HFC-134a (R-'134a)to avoid leakage.. lmmediately after using the oil, reinstallthe cap
on the container, and seal it to avoid moisture
absorption.. Do not spillthe refrigerant oil onthevehicle;it
may damage the paint. lf the refrigerant oil
contacts the paint, wash it off immediately.. Be careful not to damage the radiator or the
condenser fins when installing the condenser.. Charge the system (see page 21-55).
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Refrigerant Recovery
Air conditioning refrigerant or lubricant vapor
can irritate your eyes, nose. or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor
Use only service equipment that is U.L.-listed and is
certified to meet the requirements of SAE J2210 to
remove HFC-134a (R-134a) from the air conditioning
system.
lf accidental system discharge occurs, ventilate the
work area before resuming service
Additional health and safety information may be
obtained from the refrigerant and lubricant
manufacturers.
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1. Connect a R-134a refrigerant recovery/recycling/
charging station {A) to the high-pressure service
port (B) and the low-pressure service port (C), as
shown, following the equipment manufacturer's
instructions.
lvleasure the amount of refrigerant oil removed
from the Ay'C system after the recovery process is
completed. Be sure to put the same amount of new
refrigerant oil back into the Ay'C system before
chargrng.
21-53