A/C System Does Not Work (09-076)

A/C SYSTEM DOES NOT WORK

TECHNICAL SERVICE BULLETIN

REVISION SUMMARY

Under PARTS INFORMATION, the clutch set and the coil set were added. Under DIAGNOSIS, steps were added for A/C compressor clutch and coil inspection.

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

A/C Service Kit A (For VINs starting with JHL or SHS):

P/N 80010-S9A-305

(Includes compressor, discharge O-ring, suction O-ring, condenser O-ring, and desiccant bag.)

A/C Service Kit B (for VINs starting with JHL):

P/N 80010-S9A-306

(Includes compressor, condenser, receiver/dryer, desiccant bag, and discharge line.)

A/C Service Kit B (for VINs starting with SHS):

P/N 80010-S9A-406

(Includes compressor, condenser, receiver/dryer, desiccant bag, and discharge line.)

A/C Service Kit C (for VINs starting with JHL):

P/N 80010-S9A-307

(Includes compressor, condenser, receiver/dryer, desiccant bag, expansion valve, expansion valve O-rings, evaporator, A/C line, receiver line A, receiver line B, suction hose, and discharge line.)

A/C Service Kit C (for VINs starting with SHS):

P/N 80010-S9A-407

(Includes compressor, condenser, receiver/dryer, desiccant bag, expansion valve, expansion valve O-rings, evaporator, A/C line, receiver line A, receiver line B, suction hose, and discharge line.)

Clutch Set (if needed): P/N 38900-PNB-006

Coil Set (if needed): P/N 38924-PND-006

WARRANTY CLAIM INFORMATION

The normal warranty applies.

OP#	Description	FRT
614021	Diagnose the A/C system, and do REPAIR PROCEDURE A.	3.2
614022	Diagnose the A/C system, and do REPAIR PROCEDURE B.	3.3
614023	Diagnose the A/C system, and do REPAIR PROCEDURE C.	5.8

Failed Part:	P/N 38810-PNB-006
Defect Code:	08103
Symptom Code:	03214
Skill Level:	Repair Technician

DIAGNOSIS

• Refrigerant Recovery/Recharging
• Battery Disconnection/Reconnection
• Front Bumper Removal
• Radiator 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. Add the recommended refrigerant oil in the amount listed below when you replace any of the following parts.
   NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system.
   • Condenser: 25 ml (5/16 fl.oz.)
   • Evaporator: 40 ml (1 1/3 fl.oz.)
   • Line or hose: 10 ml (1/3 fl.oz.)
   • Compressor: Subtract the volume of oil drained from the removed compressor from 130 ml (4 1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 ml (4 1/3 fl.oz.) - Volume of oil drained from 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.) from the new compressor.

   Example:

   New Compressor oil amount 130 ml 

   Amount of oil drained from old compressor 100 ml 

   130 ml

   -100 ml

   130 ml is the amount to remove from the new compressor.

   NOTE: Failure to add and/or balance the refrigerant oil in the system may cause poor A/C performance and/or premature compressor failure.
2. Disconnect the battery.
3. Remove the front bumper.
4. Remove the radiator.
5. Remove the drive belt.
6. Remove the auto-tensioner.
7. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator.
8. Remove the alternator (three bolts).
9. Disconnect the compressor clutch connector, remove the suction line bolt and the discharge line nut, then disconnect the suction line and the discharge line from the compressor.
10. Remove the compressor (4 bolts).
11. Inspect the A/C compressor clutch and coil. If either part fails the inspection, replace that part. If these parts are good, reuse them on the new compressor.
12. Swab the inside of the hose passages on the suction and the discharge ports of the compressor.
    • If you find any metal particles, or dark gray or black residue, go to REPAIR PROCEDURE C .
    • If you find any light gray residue, metal shavings, particles, or debris, go to step 13.
13. Remove the discharge line bolt, then disconnect the discharge line from the condenser.
14. Swab the inside of the discharge line and the condenser passage.
    • If any metal shavings or other debris are found, the condenser and the discharge line must be replaced during the course of this repair. Go to step 15.
    • If no residue or metal is found, go to step 15.
15. Remove the cap from the bottom of the condenser, then remove the filter and the desiccant bag.
16. Inspect the desiccant bag for residue. Use the examples below to help determine the correct repair procedure:
    • If the desiccant bag is clean, go to REPAIR PROCEDURE A .
    • If the desiccant bag is slightly contaminated, go to REPAIR PROCEDURE B .
    • If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C 

REPAIR PROCEDURE A (A/C SERVICE KIT A)

1. Install a new clutch and coil (if needed) or the original to a new compressor. Install the compressor, then torque its mounting bolts to 22 N.m (16 lb-ft).  Connect the discharge and suction lines with new O-rings, and torque the line nut and the bolt to 9.8 N.m (7.2 lb-ft).  Reconnect the compressor clutch connector.
2. Install new O-rings on the condenser discharge line and condenser line ends, then install a new desiccant bag and a new filter.
3. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 
4. Reinstall the auto-tensioner.
5. Reinstall the drive belt.
6. Reinstall the radiator.
7. Reinstall the front bumper, and replace any damaged mounting clips.
8. Reconnect the battery.
9. Add the recommended refrigerant oil in the amount listed when you replace the following parts.
   NOTE: The new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system.
   • Line or hose: 10 ml (1/3 fl.oz.)
   • Compressor: For compressor replacement, subtract the volume of oil drained from the removed compressor from 130 ml (4 1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 ml (4 1/3 fl.oz.) - Volume of oil drained from the 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.) from the new compressor.
10. 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.

REPAIR PROCEDURE B (A/C SERVICE KIT B)

1. Disconnect the discharge line and receiver line B from the condenser.
2. Remove the condenser bolts and the mounting brackets, then remove the condenser by lifting it up.
3. Remove the discharge line
4. Add the recommended refrigerant oil in the amount listed when you replace the following parts.
   NOTE: The new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system.
   • Condenser: 25 ml (5/16 fl.oz.)
   • Evaporator: 40 ml (1 1/3 fl.oz.)
   • Line or hose: 10 ml (1/3 fl.oz.)
   • Compressor: For compressor replacement, subtract the volume of oil drained from the removed compressor from 130 ml (4 1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 ml (4 1/3 fl.oz.) - Volume of oil drained from 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.) from the new compressor.
5. Install a new desiccant bag, condenser, discharge line, and O-rings. Torque the condenser brackets to 9.8 N.m (7.2 lb-ft).  Torque the condenser bolts and the discharge line bolts to 9.8 N.m (7.2 lb-ft). 
   NOTE: Apply a thin coat of refrigerant oil to the O-rings before installation.
6. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the mounting bolts to 22 N.m (16 lb-ft). 
7. Install the suction line and the new discharge line to the compressor using new O-rings. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 
8. Install receiver line A and receiver line B using new O-rings.
9. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 
10. Reinstall the auto-tensioner.
11. Reinstall the drive belt.
12. Reinstall the radiator.
13. Reinstall the front bumper.
14. Reconnect the battery.
15. Recharge the A/C system with a recovery/recycling/recharge station. Recharging includes these steps:
    • Evacuate the system.
    • Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only Keihin SP-10 refrigerant oil.
    • 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.

REPAIR PROCEDURE C (A/C SERVICE KIT C)

1. Disconnect the discharge line and receiver line B from the condenser.
2. Remove the condenser bolts and the mounting brackets, then remove the condenser by lifting it up.
3. Remove the suction hose, the discharge line, the A/C line, receiver line A, and receiver line B.
4. Remove the expansion valve, and the expansion valve O-rings.
5. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core.
6. 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.
7. Remove the right kick panel and the glove box.
8. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace
9. Remove the relays, then remove the bolts and the glove box frame
10. Remove the ECM/PCM.
11. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips.
12. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit.
13. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover.
14. Carefully pull out the evaporator.
15. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover.
16. Reinstall the blower unit.
17. Reinstall the ECM/PCM.
18. Reinstall the dashboard undercover.
19. Reinstall the relays.
20. Reinstall the kick panel and the glove box.
21. Add the recommended refrigerant oil in the amount listed when you replace the following parts.
    NOTE: The new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system.
    • Condenser: 25 ml (5/16 fl.oz)
    • Evaporator: 40 ml (1 1/3 fl.oz)
    • Line or hose: 10 ml (1/3 fl.oz)
    • Compressor: For compressor replacement, subtract the volume of oil drained from the removed compressor from 130 ml (4 1/3 fl.oz), and drain the calculated volume of oil from the new compressor: 130 ml (4 1/3 fl.oz) - Volume of oil removed from 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) from the new compressor.
22. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 
23. Reinstall the expansion valve.
24. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge line, and new O-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 O-rings before installation.
25. Install a new receiver line A and a new receiver line B.
26. 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). 
27. Install a new suction line and a new discharge line to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 
28. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 
29. Reinstall the auto-tensioner.
30. Reinstall the drive belt.
31. Reinstall the radiator.
32. Reinstall the front bumper.
33. Reconnect the battery.
34. 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.