Honda CIVIC AIR CONDITIONER (2002), 80000-S5D-A22, 80000-S5D-C22 Installation Instructions Manual

INSTALLATION INSTRUCTIONS

Accessory Application Publications No.

AIR CONDITIONER

CIVIC

2- AND 4-DOOR

AII 24158

Issue Date

SEP 2002

What’s New

The installation instructions for the 2003 Civic A/C are the same as the 2002 model. However, the A/C kit numbers are different because of improvements to the wire length on the compressor:

• 80000-S5D-A22 for U.S.

• 80000-S5D-C22 for Canada

TOOLS AND SUPPLIES REQUIRED

Duct tape Hacksaw blade Trim clip remover Open-end wrench set Screwdrivers Socket wrench set Torque wrench Tension gauge Refrigerant oil (R-12 mineral oil or R-134a PAG oil) Fender, floor, and seat covers HFC-134a refrigerant recovery/recycling/charging

station Gloves Eye protection (face shield or safety goggles) Electronic leak detector

NOTICE

S Use only

HFC-134a in this system; do not

use CFC 12 (Freon); do not install parts designed for use in a

CFC system.

S Use a charging station. A/C charging

stations and refrigerant recovery/recycling stations minimize the release of

HFCs to the atmosphere. Use them for all A/C

CFCs and

charging and service work according to the manufacturers’ instructions.

S Do not overcharge. This system requires

only the amount of

HFC-134a refrigerant

shown below. If you overcharge the system, the engine and the

A/C will malfunction.

500 to 550 grams

0.50 to 0.55 kilograms

1.1 to 1.2 pounds

17.6 to 19.4 ounces

INSTALLATION

Customer Information: The information in these instructions is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your car. These procedures should not be attempted by doĆitĆyourselfers."

NOTE: S Make sure you have the anti-theft code for

the audio system.

S Write down the customer’s radio station

presets; the radio memory will be erased

when you disconnect the battery.

S Make sure you install the right part. Use the

illustrations on pages 2 and 3 as a guide to check the parts before you install them.

S Don’t remove plugs and caps from fittings

until the parts are ready to connect. This

will keep out moisture and dirt which could cause wear and damage.

During Installation: S Before you connect any line or hose,

check and lube its O-ring. Make sure the

O-ring is on the fitting, put a few drops of refrigerant oil on the O-ring, then connect the fitting.

S You may use either type of refrigerant oil to

lubricate O-rings and fittings.

S If you add or replace refrigerant oil in the

system, use only this

PAG oil: Sanden SP-10,

P/N 38897-P13-A01.

S Route and secure the lines and hoses

properly; maintain clearance between them

and surrounding parts.

S Use two wrenches to tighten or loosen

fittings; hold one fitting in place while you

tighten the other one against it.

NOTICE

Don’t overtighten; you could

damage the fittings. Before you tighten a

fitting, check the torque listed for it. If leaks are caused by faulty O-rings, overtightening the fitting won’t help.

S Before you connect each electrical

connector, check its terminals. Make sure

the terminals aren’t bent or out of place.

Group A

GROUP PAR T P/N QUANTITY

79601ĆS5AĆ003

53747ĆSA5Ć003

80290ĆS5DĆA01

80210ĆS5DĆG02

80560ĆS5AĆ941

80271ĆS5AĆ000

80295ĆS5DĆA01

Drain hose clip A/C button

Evaporator Drain hose Dust and pollen filter A Dust and pollen filter B Evaporator sensor

Wire ties Condenser fan assembly

Compressor Compressor belt Heat insulator Condenser assembly Right condenser bracket Left condenser bracket Suction line Discharge hose A/C suction line and receiver line B Condenser line Receiver line Receiver Suction hose clamp A Suction hose bracket Suction line bracket Receiver line clip A Receiver line clip B A/C wire harness Flange bolts, 8 x 100 mm Ground bolt, 6 x 12 mm (brassĆcolored) Paint cutting nut, 6 mm (yellowĆtinted) WasherĆbolt, 6 x 12 mm (yellowĆtinted) WasherĆbolts, 6 x 16 mm (grayĆcolored) Flange bolts, 6 x 12 mm (yellowĆtinted) Flange bolts, 6 x 25 mm (yellowĆtinted) Flange bolt, 6 x 30 mm (yellowĆtinted)

Power relay (4P) Information label (Canada)

Information label (USA) A/C kit identification label (USA)

53747ĆSA5Ć003 79601ĆS5AĆ003

80210ĆS5DĆG03

80271ĆS5AĆ000 80290ĆS5DĆA01 80295ĆS5DĆA01

80560ĆS5AĆ941

08F13ĆS84100013

38605ĆPMMĆA12

38800ĆPLMĆA12

38920ĆPLRĆ004 38935ĆPLMĆA00

80100ĆS5AĆ003

80107ĆS5AĆ000

80108ĆS5AĆ000

80311ĆS5DĆA12

80315ĆS5AĆ013 80320ĆS5DĆA12

80331ĆS5DĆA11

80341ĆS5DĆA11 80350ĆS5DĆA01

80360ĆS5AĆA00

80361ĆS5AĆA00

80363ĆS5AĆA01

80381ĆS5AĆA01 80387ĆSM4ĆA01

80460ĆS5AĆA00

90023ĆP2AĆ000

90153ĆSE0Ć003

90361ĆSV4Ć003 93403Ć06012Ć08 93403Ć06016Ć05 95701Ć06012Ć08 95701Ć06025Ć08 95701Ć06030Ć08

39794ĆS0KĆA01

80050ĆSP0Ć000 80050ĆSR3ĆH00 8005XĆS5DĆA21

1 1 1 1 1 1 1

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 3 1 7 2 4 1

2 1 1 1

Group C

39794-S0K-A01

2 of 24

8005XĆS5DĆA21

AII 24158 (0209)

80050ĆSR3ĆH00

80050ĆSP0Ć000

Group B

90023ĆP2AĆ000

(YellowĆtinted) 95701Ć06030Ć08

93403Ć06016Ć05 (GrayĆcolored)

38800ĆPLMĆA02

(YellowĆtinted) 90361ĆSV4Ć003

90361ĆSV4Ć003 (YellowĆtinted)

80311ĆS5DĆA12

(Yellow tinted)

95701Ć06012Ć08

80320ĆS5DĆA12

38935ĆPLMĆA00

80361ĆS5AĆA00

(YellowĆtinted) 93403Ć06012Ć08

80381ĆS5AĆA01

38920ĆPLRĆ004

80360ĆS5AĆA00

80387ĆSM4ĆA01

80460ĆS5AĆA00

(YellowĆtinted) 95701Ć06025Ć08

08F13-S8410013

93403Ć06016Ć05 (GrayĆcolored)

(YellowĆtinted) 95701Ć06025Ć08

80331ĆS5DĆA11

80341ĆS5DĆA11

93403Ć06016Ć05 (Gray colored)

(YellowĆtinted) 95701Ć06025Ć08

80315ĆS5AĆ013

93403Ć06016Ć05 (GrayĆcolored)

80100ĆS5AĆ003

(BrassĆcolored) 90153ĆSE0Ć003

80363ĆS5AĆA01

38605ĆPMMĆA11

80107ĆS5AĆ000

93403Ć06016Ć05 (GrayĆcolored)

(GrayĆcolored) 93403Ć06016Ć05

80108ĆS5AĆ000

80350ĆS5DĆA01

AII 24158 (0209)

3 of 24

1. Disconnect the battery.

Remove the negative cable from the battery.

2. Remove the driver’s dashboard lower cover and the under-dash fuse/relay box.

4 of 24

AII 24158 (0209)

3. Remove the passenger’s dashboard lower cover and the glove box.

Remove the cover by pulling down on its front edge to release the three clips, then pulling it toward you to release the two rear pins.

Remove the passenger’s kick panel (two clips).

AII 24158 (0209)

5 of 24

4. Remove the glove box frame and plastic cross-piece.

Release these two lock tabs, then remove the relay assembly from the glove box frame.

Place protective tape on the driver’s side of the glove box opening.

Remove and discard this 5 mm washer bolt.

Remove the glove box frame (four bolts).

Move aside any vehicle harness that may be in the way, and use a hacksaw blade to carefully cut through the plastic cross-piece in the areas shown. Remove and discard the plastic cross-piece and the protective tape.

Place protective tape (duct tape) on the passenger’s side of the glove box opening.

6 of 24

AII 24158 (0209)

5. Remove the ECM/PCM unit and the bracket.

Remove the ECM/PCM.

Disconnect these connectors from the ECM/PCM.

Remove the main harness connector from its bracket.

AII 24158 (0209)

7 of 24

6. Prepare to install the evaporator.

Disconnect the recirculation control motor 7P connector.

Remove this wire harness clip from the blower.

BLOWER

VEHICLE HARNESS

Disconnect the power transistor 4P connector.

Remove these wire harness clips from the blower.

Remove and save these washer bolts.

Disconnect the blower motor 2P connector.

Remove and save this 6 x 20 mm washer bolt.

Remove and save this paintcutting 6 mm nut and 6 x 16 mm washer-bolt.

8 of 24

AII 24158 (0209)

Remove the blower from the dashboard.

+ 16 hidden pages

Honda CIVIC AIR CONDITIONER (2002), 80000-S5D-A22, 80000-S5D-C22 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual