Friday, January 11, 2008

Climate Control System Component Location


Power relay test

Power Relays Test

Use this chart to identify the type of relay, then do the test listed for it.
NOTE: See page 22-102 for the turn signal/hazard flasher control circuit input test.


Normally-open type A:
Check for continuity between the terminals.
  • There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals.
  • There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected.


    type 1:


    type 2:

    · PGM-FI main relay 1
    · PGM-FI main relay 2


    type 1:


    type 2:


    Normally-open type B:

    Check for continuity between the terminals.
  • There should be continuity between the No. 1 and No. 3 terminals when power and ground are connected to the No. 2 and No. 4 terminals.
  • There should be no continuity between the No. 1 and No. 3 terminals when power is disconnected.




    Five terminal type

    Check for continuity between the terminals.

  • There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals.
  • There should be continuity between the No. 1 and No. 4 terminals when power is disconnected.



  • A/C Compressor Clutch Circuit Troubleshooting

    1. Check the No. 11 (30A) fuse in the under-hood fuse/relay box, and the No. 22 (30A) fuse in the under-dash fuse/relay box.
    Are the fuses OK?
    YES - Go to 2.
    NO - Replace the fuse(s), and recheck.

    2. Check the engine coolant temperature (use the Honda PGM Tester PGM-FI data list if possible).
    Is the coolant temperature above nomal?
    YES - Troubleshoot and repair the cause of the high engine coolant temperature.
    NO - Go to 3.

    3. Remove the compressor clutch relay from the under-hood fuse/relay box, and test it.
    Is the relay OK?
    YES - Go to 4.
    NO - Replace the compressor clutch relay.
    4. Measure the voltage between the No. 2 terminal of the compressor clutch relay 5P socket and body ground.


    Is there battery voltage?
    YES - Go to 5.
    NO - Replace the under-hood fuse/relay box.

    5. Connect the No. 1 and No. 2 terminals of the compressor clutch relay 5P socket with a jumper wire.


    Does the compressor clutch click ?
    YES - Go to 6.
    NO - Go to 14.

    6. Disconnect the jumper wire.

    7. Turn the ignition switch ON (II).

    8. Measure the voltage between the No. 5 terminal of the compressor clutch relay 5P socket and body ground.



    Is there battery voltage?
    YES - Go to 9.
    NO - Repair open in the wire between the No. 22 fuse in the under-dash fuse/relay box and the compressor clutch relay.

    9. Turn the ignition switch OFF.

    10. Reinstall the compressor clutch relay.

    11. Make sure the A/C switch is OFF.

    12. Turn the ignition switch ON (II).

    13. Measure the voltage between the No. 18 terminal of ECM/PCM connector E (31P) and body ground with the ECM/PCM connectors connected.


    Is there battery voltage?

    YES - Check for loose wires or poor connections at ECM/PCM connector E (31P). If the connections are good, substitute a known-good ECM/ PCM, and recheck. If the symptom/indication goes away, replace the original ECM/PCM.
    NO - Repair open in the wire between the compressor clutch relay and the ECM/ PCM.

    14. Disconnect the jumper wire.

    15. Disconnect the compressor clutch 1P connector.

    16. Check for continuity between the No. 1 terminal of the compressor clutch relay 5P socket and the No. 1 terminal of the compressor clutch 1P connector.


    Is there continuity?
    YES - Check the compressor clutch clearance, the thermal protector, and the compressor clutch field coil.
    NO - Repair open in the wire between the compressor clutch relay and the compressor clutch.

    A/C Refrigerant Oil Replacement

    Recommended PAG oil: KEIHIN SP-10:
  • P/N 38897-P13-003: 120 mL (4 fl·oz, 4.2 Imp·oz)
  • P/N 38898-P13-003: 250 mL (8 1/3 fl·oz, 8.8 Imp·oz)
  • P/N 38899-P13-A01: 40 mL (1 1/3 fl·oz, 1.4 Imp·oz)

    Add the recommended refrigerant oil in the amount listed if you replace any of the following parts.
  • To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
  • Immediately after using the oil, reinstall 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 it gets on the paint, wash it off immediately.

    Condenser . 25 mL (5/6 fl·oz, 0.9 lmp·oz)
    Evaporator . 35 mL (1 1/6 fl·oz, 1.2 lmp·oz)
    Line or hose . 10 mL (1/3 fl·oz, 0.4 lmp·oz)
    Leakage repair . 25 mL (5/6 fl·oz, 0.9 lmp·oz)
    Compressor . For compressor replacement, subtract the volume of oil drained from the removed compressor from 85 mL (2 5/6 fl·oz, 3.0 lmp·oz), and drain the calculated volume of oil from the new compressor: 85 mL ( 2 5/6 fl·oz, 3.0 lmp·oz) - Volume of removed compressor = Volume to drain from new compressor.

    NOTE: Even if no oil is drained from the removed compressor, don't drain more than 50 mL (1 2/3 fl·oz, 1.8 lmp·oz) from the new compressor.


    NOTE: LHD type is shown, RHD type is similar.


    (1)Discharge hose to the compressor (6 x 1.0 mm): 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
    (2)Discharge hose to the condenser (6 x 1.0 mm): 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
    (3)Receiver line to the condenser (6 x 1.0 mm): 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
    (4)Suction hose to the compressor (6 x 1.0 mm): 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
    (5)Compressor to the compressor bracket (8 x 1.25 mm): 22 N·m (2.2 kgf·m, 16 lbf·ft)
  • Drive Belt Inspection and Adjustment

    Special Tools Required
    Belt tension gauge ( 07JGG-0010100)


    Belt Tension Gauge Method
    Inspection
    1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2.

    Tension: Used Belt: 440-590 N (45-60 kgf, 99-130 lbf)
    New Belt: 981-1,130 N (100-115 kgf, 220-254 lbf)

    With A/C compressor:



    Without A/C compressor:


    Adjustment
    2. Loosen the lock bolt (A) and mounting bolt (B).

    3. Turn the adjusting bolt (C) to obtain the proper belt tension, then retighten the lock bolt and mounting bolt.

    4. Recheck the belt tension.

    5. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification.

    Deflection Method
    Inspection
    1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the A/C compressor (alternator for without A/C compressor) and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2.

    Deflection: With A/C compressor:
    Used Belt: 5.5-8.5 mm (0.22-0.33 in.)
    New Belt: 3.5-5.0 mm (0.14-0.20 in.)
    Without A/C compressor:
    Used Belt: 7.5-10.5 mm (0.30-0.41 in.)
    New Belt: 4.5-6.0 mm (0.18-0.24 in.)

    With A/C compressor:



    Without A/C compressor:


    Adjustment
    2. Loosen the lock bolt (A) and mounting bolt (B).

    3. Turn the adjusting bolt (C) to obtain the proper belt tension, then retighten the lock bolt and mounting bolt.

    4. Recheck the belt tension.

    5. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification.

    A/C Compressor Replacement

    1. If 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. Disconnect the negative cable from the battery.

    3. Recover the refrigerant with a recovery/recycling/charging station.
    4. Remove the splash shield.


    5. Remove the drive belt.
    5.1Loosen the lock bolt (A), mounting bolt (B) and adjusting bolt (C),then remove the drive belt (D).

    5.2 Install the drive belt in the reverse order of removal.

    5.3 Adjust the drive belt tension

    6. Remove the bolts, then disconnect the suction line (A) and the discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

    7. Remove the mounting bolts and the compressor.

    8. Install the compressor in the reverse order of removal, and note these items:

  • If you're installing a new compressor, you must calculate the amount of refrigerant oil to be removed from it.
  • 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 right O-rings for HFC-134a (R-134a) to avoid leakage.
  • Use refrigerant oil (KEIHIN SP-10) for HFC-134a KEIHIN spiral type compressor only.
  • To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
  • Immediately after using the oil, reinstall 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.
  • Charge the system.
  • A/C 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).

    2. Replace the thermal protector (A) with a new one, and apply silicone sealant (B) to the bottom of the thermal protector.

    3. Install in the reverse order of removal.

    A/C System Tests

    Pressure Test

    Performance Test






    The performance test will help determine if the air conditioner system is operating within specifications.

    Use only service equipment for refrigerant HFC-134a (R-134a).

    If accidental system discharge occurs, ventilate 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.

    1. Connect a R-134a refrigerant recover/recycling/charging station to the high-pressure service port and the low-pressure service port, following the equipment manufacturer's instructions.

    2. Determine the relative humidity and air temperature.

    3. Insert a thermometer in the center vent.

    4. Test conditions:
  • Avoid direct sunlight.
  • Open the hood.
  • Open the front doors.
  • Set the temperature control dial to Max Cool, the mode control dial to Vent and the recirculation control lever to Recirculate.
  • Turn the A/C switch on and the fan switch on Max.
  • Run the engine at 1,500 rpm (min-1).
  • No driver or passengers in vehicle.

    5. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the thermometer in the center vent, the intake temperature near the blower unit behind the glove box and the high and low system pressure from the A/C gauges.

    6. To complete the charts:
  • Mark the delivery temperature along the vertical line.
  • Mark the 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.
  • From each point, draw a horizontal line across the delivery temperature.
  • The delivery temperature should fall between the two lines.
  • Complete the low-side pressure test and high-side pressure test in the same way.
  • Any measurements outside the line may indicate the need for further inspection.

  • A/C Refrigerant Leak Test



    Use only service equipment for refrigerant HFC-134a (R-134a).

    If accidental system discharge occurs, ventilate 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.

    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.

    2. Open 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:
    400 to 450 g
    0.40 to 0.45 kg
    0.9 to 1.0 lbs
    14.1 to 15.9 oz


    3. 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.

    4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), recover the system.

    5. After checking and repairing leaks, the system must be evacuated.

    A/C System Evacuation


    Use only service equipment for refrigerant HFC-134a (R-134a).

    If accidental system discharge occurs, ventilate work area before resuming service.

    Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

    1. When an A/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. (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)

    2. 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. Evacuate the system.


    3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks.

    A/C System Charging


    Use only service equipment for refrigerant HFC-134a (R-134a).

    If accidental system discharge occurs, ventilate 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 port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer¢s instructions.

    2. Evacuate the system.

    3. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only KEIHIN SP-10 refrigerant oil.

    4. 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:
    400 to 450 g
    0.40 to 0.45 kg
    0.9 to 1.0 lbs
    14.1 to 15.9 oz


    5. Check for refrigerant leaks.

    6. Check for system performance.

    A/C Refrigerant Recovery


    Use only service equipment for refrigerant HFC-134a (R-134a).

    If accidental system discharge occurs, ventilate 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 port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer¢s instructions.


    2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging.

    A/C Compressor Relief Valve Replacement

    1. Recover the refrigerant with a recovery/recycling/charging station.

    2. Remove the relief valve (A) and the O-ring (B). Plug the opening to keep foreign matter from entering the system and the compressor oil from running out.


    3. Clean the mating surfaces.

    4. Replace the O-ring with a new one at the relief valve, and apply a thin coat of refrigerant oil before installing it.

    5. Remove the plug, and install and tighten the relief valve.

    6. Charge the system.

    A/C Compressor Clutch Check

    1. Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set.

    2. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag.



    3. Measure the clearance between the rotor pulley (A) and the armature plate (B) all the way around. If the clearance is not within specified limits, remove the armature plate and add or remove shims as needed to increase or decrease clearance.

    Clearance: 0.5±0.15 mm (0.020±0.006 in.)
    NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm.



    4. Release the field coil connector from the holder, then disconnect it. Check the thermal protector for continuity. If there is no continuity, replace the thermal protector.

    NOTE: The thermal protector will have no continuity above 122 to 132°C (252 to 270°F). When the temperature drops below 116 to 104°C (241 to 219°F), the thermal protector will have continuity.





    5. Check resistance of the field coil. If resistance is not within specifications, replace the field coil.

    Field Coil Resistance: 3.05-3.35 ohms at 20°C 68°F)