Compressor Clutch: Testing and Inspection
Service Information
A/C Compressor Clutch Check
*These tools are available through the Honda Tool and Equipment Program; call 888-424-6857
Removal
WARNING:
The IMA motor power cables carry high voltage when the engine is running or the IMA system is energized. To avoid serious injury from electrical shock, do not start the engine with the IMA motor power cables disconnected.
CAUTION:
* 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.
IMA components are located in this area. The IMA is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the IMA service precautions High Voltage Safety before doing repairs or service.
NOTE:
* If 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.
* Do not install an A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure.
1. Vehicle - Lift
1. Raise the vehicle on a lift, and make sure it is securely supported.
2. Glove Box - Move
1. Lower the glove box (A).
3. R134a Refrigerant Recovery/Recycling/Charging Station - Connection
1. Connect an 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.
4. A/C Refrigerant - Recovery
1. Recover the refrigerant from the A/C system.
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.
5. Rear Seat Cushion
1. Remove the bolt (A) securing the rear seat cushion (B).
2. While pushing down the rear seat cushion (A), pull out on the seat hook handles (B) to release the hooks (C).
3. Remove the rear seat cushion.
6. Rear Seat-Back
1. Remove all of the rear head restraints.
2. Release the rear center seat belt (A) from the rear center seat belt guide (B).
3. Remove the bolts (A) securing the rear seat-back (B).
4. Lift up the rear seat-back (A) to release the seat legator hooks (B) from the brackets (C) on the body, then remove the seat-back.
7. IMA Battery Main Switch - OFF
1. Turn the ignition switch to LOCK (0).
2. Remove the battery module switch lid (A) from the IPU cover.
3. Turn the battery module switch (B) OFF, then check that the bolt (C) is showing.
4. Wait at least 5 minutes to allow the PDU capacitors to discharge.
8. Drive Belt
1. Move the auto-tensioner (A) to relieve tension from the drive belt (B).
2. Remove the drive belt.
9. Engine Cover
1. Remove the engine cover.
10. Intake Air Resonator
1. Remove the intake air resonator.
11. Intake Air Duct
1. Remove the intake air duct.
12. Intake Air Pipe
1. Remove the intake air pipe.
13. Throttle Body - Move
1. Remove the throttle body without disconnecting the hoses.
14. Engine Undercover
1. Remove the engine undercover (A).
15. Intake Manifold Bracket
1. Remove the intake manifold bracket mounting bolts.
16. Intake Manifold Chamber Assembly
1. Disconnect the connector (A) and the PCV hose (B).
2. Remove the intake manifold chamber (C).
17. A/C Compressor Peripheral Assembly
1. Remove the shield connector cover (A).
2. Slide the retainer (B).
3. Remove the harness clips (C).
4. Remove the terminal (A).
5. Remove the harness clips (B).
6. Remove the bolt (A).
18. A/C Compressor
1. Disconnect the connector (A).
2. Disconnect the suction hose (B) and the discharge hose (C).
NOTE: Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
3. Remove the A/C compressor (A).
4. Pull out on the power cable (A), then lift up the A/C compressor (B).
Check
1. 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. Inspect the friction surfaces and the compressor shaft hub for excess oil. If excess oil is present, and it is not from the engine or power steering system, then the compressor shaft seal is leaking. Replace the A/C compressor.
3. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Also check for grease leakage from the bearing. Replace the clutch set with a new one if it is noisy, has excessive play/drag.
NOTE: The rotor pulley and the armature plate were mated at the factory by a burnishing operation. Always replace the rotor pulley and the plate as a set. Replacing only one part of the clutch set will cause clutch slippage.
4. 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: 0.35-0.65mm (0.014-0.025 in)
NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm.
5. Measure the resistance between the A/C compressor clutch connector terminal No. 2 and the A/C compressor housing. If resistance is not within specifications, replace the field coil.
Field Coil Resistance: 3.35-3.65 Ohms at 68 °F (20 °C)
6. Remove the holder (A).
7. Disconnect the connectors (B).
8. Check the thermal protector for continuity. If there is no continuity, replace the thermal protector.
NOTE: The thermal protector will have no continuity above about 252 to 262 °F (122 to 128 °C). When the temperature drops below about 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity.
9. Check the thermal fuse for continuity between the A/C compressor clutch connector terminal No. 3 and the field coil 1P connector (BLACK) (A). If there is no continuity, replace the field coil.
Installation
WARNING:
The IMA motor power cables carry high voltage when the engine is running or the IMA system is energized. To avoid serious injury from electrical shock, do not start the engine with the IMA motor power cables disconnected.
CAUTION:
* 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.
* Do not operate the leak detector near flammable vapors. Its sensor operates at high temperatures, and could ignite the vapors, resulting in personal injury and/or damage to the equipment.
IMA components are located in this area. The IMA is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the IMA service precautions High Voltage Safety before doing repairs or service.
NOTE:
* If an 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.
* Check the system for leaks using an R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better.
* Do not install an A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure.
* Before installing a new A/C compressor, adjust the A/C compressor oil level.
* Inspect the A/C lines for any signs of contamination.
* If you're installing a new A/C compressor, you must calculate the amount of refrigerant oil to be removed from it. A new A/C compressor comes with a full charge of oil.
* Use only SANDEN SE-10Y POE refrigerant oil. Using the wrong refrigerant oil can be a safety hazard.
* 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.
* Immediately after using the oil, dispose of any remaining oil in the container. The oil rapidly absorbs moisture and has a short shelf life.
* 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.
* Be careful not to damage the radiator fins when installing the A/C compressor, the alternator or the A/C condenser fan shroud.
1. A/C Compressor
1. Get down the A/C compressor (A) and the power cable (B).
2. Install the A/C compressor (A).
NOTE: Install the bolts loosely, then tighten the mounting bolts (B), (C), and (D) in that order when installing.
3. Remove the plugs or caps.
4. Connect the suction hose (A) with a new O-ring (B).
5. Connect the discharge hose (C) with a new O-ring (D).
6. Connect the connector (E).
2. A/C Compressor Peripheral Assembly
1. Install the bolt (A).
2. Install the terminal (A).
3. Connect the harness clips (B).
4. Install the shield connector cover (A).
5. Install the harness clips (B).
3. Intake Manifold Chamber Assembly
1. Install the intake manifold chamber (A) with new gaskets (B).
2. Connect the connector (C) and the PCV hose (D).
4. Intake Manifold Bracket
1. Install the intake manifold bracket mounting bolts.
5. Engine Undercover
1. Install the engine undercover (A).
6. Throttle Body - Move
1. Install the throttle body (A) with new gasket (B).
7. Intake Air Pipe
1. Install the intake air pipe.
8. Intake Air Duct
1. Install the intake air duct.
9. Intake Air Resonator
1. Install the intake air resonator.
10. Engine Cover
1. Install the engine cover.
11. Drive Belt
1. Move the auto-tensioner (A).
2. Install the drive belt (B).
12. IMA Battery Main Switch - ON
1. Make sure the ignition switch is turned to LOCK (0).
2. Turn the battery module switch (A) ON.
3. Install the battery module switch lid (C) to the IPU cover.
13. Rear Seat-Back
1. Install the seat legator hooks (A) in the brackets (B) on the body.
2. Install the bolts (A) securing the rear seat-back (B).
3. Install the rear center seat belt (A) to the rear center seat belt guide (B).
4. Install all of the head restraints.
14. Rear Seat Cushion
1. Install the hooks (A) in the rear seat cushion clips (B).
2. Install the bolt (A) securing the rear seat cushion (B).
15. A/C System Evacuation
1. Evacuate the system. The vacuum pump should run for a minimum of 30 minutes to eliminate all moisture from the system. When the suction gauge reads -93.3 kPa (-700 mmHg, -27.55 inHg) for at least 30 minutes, close all valves, and turn off the vacuum pump.
2. If the suction gauge dose not reach approximately -93.3 kPa (-700 mmHg, -27.55 inHg) in 15 minutes, there is probably a large leak in the system. Partially charge the system, and check for leaks.
16. A/C Refrigerant - Charging
1. Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the A/C compressor will be damaged.
Select the appropriate units of measure for your refrigerant charging station.
17. A/C Refrigerant - Leak Check
Leak Detector Usage Tips (Refer to the Operator's Manual for complete operating instructions)
* Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
* When using the leak detector for the first time, allow it to warm up for 2 minutes with the probe in a clean atmosphere. This lets the temperature sensor in the detector stabilize.
* The calibration check should be done in the "Search 2" mode. Once that is done, the other check modes do not need calibrating.
* When leak checking through the HVAC module drain hose, avoid drawing water into the probe. Water can damage the internal pump and sensor.
* Avoid creasing the flexible probe extension. Creases can restrict air flow and give false readings.
* Because the detector recalibrates itself for ambient gases, it may be necessary to move the detector away from the leak to clear the sensor. Once the sensor has cleared, recheck the suspected leak.
* When removing the clear probe tip, be careful not to lose the flow ball.
* R-134a is heavier than air; always check below and to the sides of all potential leak sources.
* Halogen leak detectors are sensitive to chemicals: windshield washing solutions, solvents/cleaners, and some vehicle adhesives. Keep these chemicals out of the area when doing leak detection.
Fluorescent Dye Usage Tips
* Use only Tracer-Stick single dose fluorescent dye capsules from Tracerline(R). Other dyes contain solvents that may contaminate the refrigerant oil, leading to component failure.
* Adding excessive amounts of dye can damage the A/C compressor.
* PAG oil is water soluble, so condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
* After checking and repairing leaks, thoroughly clean any residual dye from the areas where leaks were found. Use GLO-AWAY dye cleaner, from Tracerline(R), and hot water to remove the dye (follow the instructions on the bottle). Residual dye stains can cause misdiagnosis of any future A/C system leaks.
* If any refrigerant dye contacts an exterior paint surface, remove it by doing this:
- Carefully wash the affected surfaces to remove any dirt, and to prevent paint scratching.
- Mix water and isopropyl alcohol in a 50/50 mixture. Soak a soft 100 % cotton towel with the water/alcohol mixture, and place the cloth on the affected areas to remove the dye.
- After removing the dye with the water/alcohol-soaked cloth, carefully wash the affected areas, and check that there is no remaining dye.
1. With the engine OFF, use a halogen leak detector first to detect the leak source. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test the following areas of the system for leaks:
2. Close the quick coupler valves, then disconnect the quick couplers from the vehicle service ports.
3. Attach the universal connect set, from the Optimax Jr. Leak Detection Kit, to the service valve fitting. Close the control valve (the black knob on the connect set).
4. Attach the charging station low pressure hose quick coupler to the service valve fitting, and open the quick coupler valve. Evacuate the connect set using the charging station vacuum pump, then close the quick coupler valve.
5. Detach the universal connect set, and install a Tracer-Stick(R) dye capsule between the connect set and the service valve fitting (see the manufacturer's instructions for more detail).
6. Attach the quick coupler on the universal connect set to the low pressure service port on the vehicle. Open the charging station low pressure hose quick coupler valve, but do not open the control valve.
7. Start the engine, and set the A/C system to maximum cooling. Open the control valve to let refrigerant and the dye enter the A/C system through the low pressure service port. Close the control valve when the Tracer-Stick(R) dye capsule is empty.
8. Run the engine and A/C system for 15 minutes to thoroughly circulate the dye. Then shut the engine off, and inspect the following areas of the system for leaks:
NOTE:
* Check for leaks in a dark work area, and use the UV light and the special glasses from the leak check kit. Other UV lights may not work well with the Tracer-Stick(R) dye.
* Small leaks may take up to 1 week of vehicle operation (with normal A/C use) to become visible.
18. A/C System - Test
1. Insert a thermometer (A) in the center vent.
2. Place a hydro-thermometer (B) near the blower unit's recirculation inlet duct.
3. Test conditions:
* Move the vehicle out of direct sunlight and let it cool down to the surrounding (ambient) temperature. If necessary, wash the vehicle to cool it down more quickly.
* The blower intake temperature must be at least 68°F (20°C).
* Open the hood.
* Open the front doors.
* Start the engine.
* Set the temperature control button to Max Cool, the mode control button to Vent, and the recirculation control button to Recirculate.
* Turn the A/C button on and the fan control button to Max.
* Run the engine at 1,500 rpm.
* No driver or passengers in vehicle.
4. Inspect the A/C components for the following conditions:
* A/C compressor clutch not engaged.
* Abnormal frost areas.
* Unusual noises.
If you observe any of these conditions, refer to the Symptom Troubleshooting Index.
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, and the discharge (high) and suction (low) pressures on the A/C gauges.
6. To complete the vent (delivery)/intake temperature chart:
* Mark the vent (delivery) temperature on the vertical line.
* Mark the a intake temperature on the bottom line.
* Draw a vertical line from the intake temperature mark.
* Draw a horizontal line from the vent (delivery) temperature mark until it intersects the vertical line.
NOTE: The vent temperature and ambient air temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection.
7. To complete the high side (discharge) pressure/intake temperature chart:
* Mark the high side (discharge) pressure on the vertical line.
* Mark the intake temperature on the bottom line.
* Draw a vertical line from the intake temperature mark.
* Draw a horizontal line from the high side (discharge) pressure mark until it intersects the vertical line.
NOTE: The high side pressure and ambient air temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection.
8. To complete the low side (suction) pressure/intake temperature chart:
* Mark the low side (suction) pressure along the vertical line.
* Mark the intake temperature along the bottom line.
* Draw a vertical line from the intake temperature mark.
* Draw a horizontal line from the low side (suction) pressure mark until it intersects the vertical line.
NOTE: The low side pressure and ambient air temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection.
19. Glove Box - Move
1. Install the glove box (A).