A/C - System is Inoperative
09-076October 14, 2010
Applies To:
2002-04 CR-V - ALL
A/C System Does Not Work
(Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY)
REVISION SUMMARY
The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly.
SYMPTOM
The A/C system does not work.
PROBABLE CAUSE
The A/C compressor failed.
CORRECTIVE ACTION
Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test.
PARTS INFORMATION
TOOL INFORMATION
A/C Compressor Kit: 07MF-000A150
WARRANTY CLAIM INFORMATION
The normal warranty applies.
Failed Part: P/N 38810-PNB-006
Defect Code: 08103
Symptom Code: 03214
Skill Level: Repair Technician
DIAGNOSIS
NOTE:
This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online:
^ Refrigerant Recovery/Recharging
^ Battery Disconnection/Reconnection
^ Front Bumper Removal
^ Radiator Reservoir Removal
^ A/C Compressor Clutch Check
^ A/C Compressor Clutch Overhaul
^ Drive Belt Replacement
^ Auto-Tensioner Replacement
^ A/C Condenser Replacement
^ ECM/PCM Removal/Installation
1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off.
2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets.
3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery.
4. Recover the refrigerant with a recovery/recycling/ charging station.
5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor:
^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6.
^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting.
6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor:
^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C.
^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7.
7. Remove the radiator reservoir.
8. Remove the drive belt.
9. Remove the auto-tensioner.
10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator.
11. Remove the alternator (three bolts).
12. Remove the front bumper.
13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser.
14. Swab the inside of the discharge line and the condenser passage.
^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15.
^ If no metal particles or debris is found, go to step 16.
15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer.
^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B.
^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C.
16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer.
^ If the desiccant bag is clean, go to REPAIR PROCEDURE A.
^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B.
REPAIR PROCEDURE A (A/C SERVICE KIT A)
1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins.
2. Check the A/C compressor clutch as described in the service manual.
3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed.
4. Adjust the amount of refrigerant oil in the new A/C compressor.
NOTE:
The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement.
Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor.
NOTE:
Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor.
Example:
When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL.
5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector.
NOTE:
Apply a thin coat of refrigerant oil to the 0-rings before installation.
6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser.
7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer.
NOTE:
Apply a thin coat of refrigerant oil to the 0-rings before installation.
8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft).
9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft).
10. Reinstall the alternator.
11. Reinstall the drive belt.
12. Reinstall the auto-tensioner.
13. Reinstall the front bumper, and replace any damaged mounting clips.
14. Reconnect the battery cables to the battery, then do the battery reconnection procedure.
15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps:
^ Evacuate the system.
^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system.
^ Check for refrigerant leaks.
^ Check the A/C performance.
^ Do the ECM/PCM idle learn procedure.
^ Do the power window control unit reset procedure.
^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets.
REPAIR PROCEDURE B (A/C SERVICE KIT B)
1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins.
2. Check the NC compressor clutch as described in the service manual.
3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed.
4. Adjust the amount of refrigerant oil in the new A/C compressor.
NOTE:
The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement.
Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor.
NOTE:
Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor.
Example:
When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL.
5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector.
NOTE:
Apply a thin coat of refrigerant oil to the 0-rings before installation.
6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser.
7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer.
NOTE:
Apply a thin coat of refrigerant oil to the 0-rings before installation.
8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft).
9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft).
10. Reinstall the alternator.
11. Reinstall the drive belt.
12. Reinstall the auto-tensioner.
13. Reinstall the front bumper, and replace any damaged mounting clips.
14. Reconnect the battery cables to the battery, then do the battery reconnection procedure.
15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps:
^ Evacuate the system.
^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system.
^ Check for refrigerant leaks.
^ Check the A/C performance.
^ Do the ECM/PCM idle learn procedure.
^ Do the power window control unit reset procedure.
^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets.
REPAIR PROCEDURE C (A/C SERVICE KIT C)
1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins.
2. Check the A/C compressor clutch as described in the service manual.
3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed.
4. Disconnect the receiver line from the condenser.
5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser.
6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B.
7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core.
8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders.
9. Remove the right kick panel and the glove box.
10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace.
11. Remove the relays, then remove the bolts and the glove box frame.
12. Remove the ECM/PCM.
13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips.
14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit.
15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover.
16. Carefully pull out the evaporator.
17. Remove the bolts from the expansion valve.
18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft).
19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover.
20. Reinstall the blower unit.
21. Reinstall the ECM/PCM.
22. Reinstall the dashboard undercover.
23. Reinstall the relays.
24. Reinstall the kick panel and the glove box.
25. Install a new suction line and a new receiver line.
Torque the line nuts to 9.8 N.m (7.2 lb-ft).
26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft).
NOTE:
Apply a thin coat of refrigerant oil to the 0-rings before installation.
27. Install a new receiver line A and a new receiver line B.
28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft).
29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft)
30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft).
31. Reinstall the auto-tensioner.
32. Reinstall the drive belt.
33. Reinstall the radiator.
34. Reinstall the front bumper.
35. Reconnect the battery.
36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps:
^ Evacuate the system.
^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system.
^ Check for refrigerant leaks.
^ Check the A/C performance.
^ Do the ECM/PCM idle learn procedure.
^ Do the power window control unit reset procedure.
^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets.
NOTE:
A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system.
Disclaimer