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Honda 2002 CIVIC AIR CONDITIONER Installation Instructions Manual

2003 civic 2-door; 2003 civic 4-door; 2002 civic 2-door; 2002 civic 4-door;.
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INSTALLATION
INSTRUCTIONS
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 CFC s and
HFC s to the atmosphere. Use them for all A/C
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
 2002 American Honda Motor Co., Inc. – All Rights Reserved
Accessory
AIR CONDITIONER
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 do it yourselfers."
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.
AII 24158 (0209)
Application
CIVIC
2- AND 4-DOOR
8000X-S5D-C22
Publications No.
AII 24158
Issue Date
SEP 2002
1 of 24

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   Summary of Contents for Honda 2002 CIVIC AIR CONDITIONER

  • Page 1

    1.1 to 1.2 pounds connector, check its terminals. Make sure 17.6 to 19.4 ounces the terminals aren’t bent or out of place. 1 of 24  2002 American Honda Motor Co., Inc. – All Rights Reserved AII 24158 (0209) 8000X-S5D-C22...

  • Page 2

    80050 SR3 H00 A/C kit identification label (USA) 8005X S5D A21 Group C 80050 SP0 000 80050 SR3 H00 8005X S5D A21 39794-S0K-A01  2002 American Honda Motor Co., Inc – All Rights Reserved 2 of 24 AII 24158 (0209)

  • Page 3

    93403 06016 05 (Gray colored) 80108 S5A 000 93403 06016 05 08F13-S8410013 (Gray colored) 93403 06016 05 (Gray colored) 80100 S5A 003 80350 S5D A01  2002 American Honda Motor Co., Inc – All Rights Reserved 3 of 24 AII 24158 (0209)

  • Page 4

    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  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 5

    Remove the edge to release the passenger’s three clips, then pulling kick panel it toward you to release (two clips). the two rear pins.  2002 American Honda Motor Co., Inc – All Rights Reserved 5 of 24 AII 24158 (0209)

  • Page 6

    Remove and discard the plastic cross-piece and the protective tape. 6 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 7

    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.  2002 American Honda Motor Co., Inc – All Rights Reserved 7 of 24 AII 24158 (0209)

  • Page 8

    6 mm nut and 6 x 16 mm power transistor motor 2P washer-bolt. 4P connector. connector. Remove these wire harness clips from the blower. Remove the blower from the dashboard. 8 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 9

    Be careful not to bend the evaporator pipes. Reinstall the expansion valve cover with the six self-tapping screws you saved.  2002 American Honda Motor Co., Inc – All Rights Reserved 9 of 24 AII 24158 (0209)

  • Page 10

    Set the blower washer bolts in steps 2 in place on the and 3 to 10 N m (7 lb-ft). lower mounting stud. 10 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 11

    Reconnect these connectors to the ECM/PCM. Reattach the main harness connector to the connector bracket. Reconnect the main harness connector.  2002 American Honda Motor Co., Inc – All Rights Reserved 11 of 24 AII 24158 (0209)

  • Page 12

    HEATER UNIT LOWER CASE FRONT Remove the blue tape securing the evaporator sensor 2P connector to the vehicle harness. 12 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 13

    Install the drain hose with the white Install the drain clip onto the drain hose. paint mark on the drain nozzle.  2002 American Honda Motor Co., Inc – All Rights Reserved 13 of 24 AII 24158 (0209)

  • Page 14

    Loosen this band. Place a shop towel over the throttle body. Remove these bolts, then remove the resonator. 14 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 15: Top View

    Release the brake booster hose clamp from the bulkhead. FLAT-TIP SCREWDRIVER Top View Release these two harness clamps from the bulkhead.  2002 American Honda Motor Co., Inc – All Rights Reserved 15 of 24 AII 24158 (0209)

  • Page 16

    Loosen this bolt; do not remove it. Loosen this bolt; don’t remove it until step 7. 16 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 17

    Set the condenser on the washer-bolt (gray-colored) condenser mounts on the 93403-06016-05. Torque the bolt front lower frame. to 10 N m (7lb-ft).  2002 American Honda Motor Co., Inc – All Rights Reserved 17 of 24 AII 24158 (0209)

  • Page 18

    Carefully set the 93403-06016-05. condenser fan Torque the bolts to assembly in place 10 N m (7 lb-ft). on the condenser fan mounts. 18 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 19

    Attach the compressor harness clip to this tab on the condenser fan shroud.  2002 American Honda Motor Co., Inc – All Rights Reserved 19 of 24 AII 24158 (0209)

  • Page 20

    5 or more minutes (A/C performance test), readjust the belt to the “Used Belt” tension. Used Belt Tension: 390 to 540 N (40 to 55 kg) 20 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 21

    6 mm paint-cutting nut (yellow-tinted), 90361-SV4-003. Torque the nut to 10 N m (7 lb-ft).  2002 American Honda Motor Co., Inc – All Rights Reserved 21 of 24 AII 24158 (0209)

  • Page 22

    Apply refrigerant oil to its O-ring, then connect the discharge hose to the compressor with the retained 6 mm flange nut. Torque the nut to 10 N m (7 lb-ft). 22 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

  • Page 23

    Reattach the vehicle harness clips to their VEHICLE HARNESS brackets. 28. Attach the labels in the locations shown. UNDER-HOOD SRS LABEL (USA) (USA) (Others)  2002 American Honda Motor Co., Inc – All Rights Reserved 23 of 24 AII 24158 (0209)

  • Page 24

    S If the system is left open, the desiccant in the (40 to 55 kg). receiver tank will become saturated with moisture, Refer to step 22 on page 20. requiring longer evacuation time. 24 of 24  2002 American Honda Motor Co., Inc – All Rights Reserved AII 24158 (0209)

This manual also for:

80000-s5d-a22, 80000-s5d-c22

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