2003 HONDA CIVIC ERS

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.
,t\
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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-li .:)-:.-- ---- - -'

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.
1!l r: i t: -:
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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

Heating and Air Conditioning
System Evacuation
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 conditioninq
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.
1. When an Ay'C system has been opened to the
atmosphere, 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.)
. Air conditioning refrigerant or lubricant vapor
can irritate your eyes, nose, or throat.. Be carefulwhen connecting service equipment.. Do not breathe refrigerant or vapor.
21-54
2. Connect a R-134a refrigerant recovery/recycling/
charging station (A)to the high-pressure servicepon (B) and the low-pressure service port (C), as
shown, following the equipment manufacturer's
instructions. Evacuate the system.
lf the low-pressure does not reach more than 93.3
kPa {700 mmHg, 27.6 in.Hg) in 15 minutes, there isprobably a leak in the system. Partially charge the
system, and check for leaks (see step 3 on page 21-
56).
-i - r4.t

System Charging
Air conditioning refrigerant or lubricant vapor
can irritate your eyes, nose, or throat.
Be carefulwhen 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.
1. Connect a R-134a refrigerant recovery/recycling/
charging station (A) to the high-pressure service
pon (B) and the low-pressure service port {C), as
shown, following the equipment manufacturer's
instructions.
2.
3.
4.
Evacuate the system (see page 21'54).
Add the same amount of new refrigerant oil to the
system that was removed during recovery. Use
only KEIHIN SP-10 refrigerant oil.
Charge the system with the specified amount of
R-134a refrigerant. Do not overcharge the system;
the compressor will be damaged.
Select the appropriate units of measure for your
refrigerant charging station.
Refrigerant capacity:
500 to 550 g
0.50 to 0.55 kg
1.10 to 1.21 lbs
17.6 to 19.4 oz
Check for refrigerant leaks (see page 21'56).
Check for system performance (see page 21-58).
21-55

Heating and Air Conditioning
Refrigerant Leak Test
Special Tool Required
Leak detector, Honda Tool and Equipment YGK-H-10PM
commerciallv available
Compressed air mixed with R-134a forms a
combustible vapor.
The vapor can burn or explode causing serious
injury.
Never use compressed air to pressure test
R-134a service equipment or vehicle air
conditioning system.
Air conditioning refrigerant or lubricant vapor
can irritate your eyes, nose, or throat.
Be carefulwhen connecting service equipment.
Do not breathe refrigerant or vapor
Use only service equipment that is U.L.-listed and is
certiified 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.
R-134a service equipment or vehicle air conditioning
systems should not be pressure tested or leak tested
with compressed air.
Additional health and safety information may be
obtained from the refrigerant and lubricant
manufacturers.
21-56
1. Connect a R-134a refrigerant recovery/recycling/
charging station (A) to the high-pressure serviceport (B) and the low-pressure service port (C), as
shown, following the equipment manufacturer's
anstructions.
Open the high pressure valve to charge the system
to the specified capacity, then close the supply
valve, and remove the charging system couplers.
Select the appropriate units of measure for your
refrigerant charging station.
Refrigerant capacity:
500 to 550 g
0.50 to 0.55 kg
1.10 to 1.21 lbs
17.6 to 19.4 oz
Check the system for leaks using a R-134a
refrigerant leak detector with an accuracy of 14 g(0.5 oz) per year or better.
lf you find leaks that require the system to be
opened (to repair or replace hoses, fittings, etc.),
recover the system.
After checking and repairing leaks, evacuate the
system.
3.