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The installation instructions for the 2005 Civic A/C arethe same as for the 2004 model.
A/C Kit:P/N 80000-S5D-A24 for U.S.P/N 80000-S5D-C24 for Canada
TOOLS AND SUPPLIES REQUIRED
Duct tape
INSTALLATION
Customer Information: The information in theseinstallation instructions is intended for use only byskilled technicians who have the proper tools,equipment, and training to correctly and safely addequipment to your vehicle. These procedures shouldnot be attempted by “do-it-yourselfers.”
NOTE:
• Make sure you have the anti-theft code for theaudio system.
• Write down the customer’s radio stationpresets. The radio memory will be erased whenyou disconnect the battery.
• Make sure you install the right part. Use theillustrations on pages 2 and 3 as a guide to checkthe parts before you install them.
• Don’t remove plugs and caps from fittings untilthe parts are ready to connect. This will keep outmoisture and dirt, which could cause wear anddamage.
Hacksaw bladeTrim clip removerOpen-end wrench setScrewdriversSocket wrench setTorque wrenchTension gaugeRefrigerant oil (R-12 mineral oil or R-134a PAG oil)Fender, floor, and seat coversHFC-134a refrigerant recovery/recycling/charging
stationGlovesEye protection (face shield or safety goggles)Electronic leak detector
NOTICE
NOTICE
During Installation:
• Before you connect any line or hose, check andlube its O-ring. Make sure the O-ring is on thefitting, put a few drops of refrigerant oil on theO-ring, then connect the fitting.
• You may use either type of refrigerant oil to lubricateO-rings and fittings.
• If you add or replace refrigerant oil in the system,use only this PAG oil: Sanden SP-10,P/N 38897-P13-A01.
• Route and secure the lines and hoses properly.Maintain clearance between them and surroundingparts.
• Use two wrenches to tighten or loosen fittings.Hold one fitting in place while you tighten the otherone against it.
Don’t overtighten; you could damagethe fittings. Before you tighten a fitting, check thetorque listed for it. If leaks are caused by faultyO-rings, overtightening the fitting won’t help.
• Before you connect each electrical connector,check its terminals. Make sure the terminals aren’tbent or out of place.
• Use only HFC-134a in this system. Do not useCFC 12 (Freon); do not install parts designed for usein a CFC system.
• Use a charging station. A/C charging stations adrefrigerant recovery/recycling stations minimize therelease of CFCs and HFCs to the atmosphere. Usethem for all A/C charging and service work accordingto the manufacturers' instructions.
• Do not overcharge. This system requires only theamount of HFC-134a refrigerant shown below. If youovercharge the system, the engine and the A/C willmalfunction.
500 to 550 grams
0.50 to 0.55 kilograms
1.1 to 1.2 pounds
17.6 to 19.4 ounces
Group A
Group C
Group Part P/N Qty
Drain hose clip 53747-SA5-003 1A/C button 79601-S5A-003 1Evaporator 80210-S5D-G03 1Drain hose 80271-S5A-000 1Dust and pollen filter A 80290-S5D-A01 1Dust and pollen filter B 80295-S5D-A01 1Evaporator sensor 80560-S5A-941 1
Wire ties 38221-SW5-300 2Condenser fan assembly 38605-PMM-A12 1Compressor 38800-PLM-A12 1Compressor belt 38920-PLR-004 1Heat insulator 38935-PLM-A00 1Condenser assembly 80100-S5A-T01 1Right condenser bracket 80107-S5A-000 1Left condenser bracket 80108-S5A-000 1Suction line 80311-S5D-A12 1Discharge hose 80315-S5A-013 1A/C suction line and receiver line B 80320-S5D-A12 1Condenser line 80331-S5D-A11 1Receiver line 80341-S5D-A02 1Receiver 80350-S5D-A01 1Suction hose clamp A 80360-S5A-A00 1Suction hose bracket 80361-S5A-A00 1Suction line bracket 80363-S5A-A01 1Receiver line clip A 80381-S5A-A01 1Receiver line clip B 91548-S5A-003 1A/C wire harness 80460-S5A-A00 1Flange bolts, 8 x 100 mm 90023-P2A-000 4Ground bolt, 6 x 12 mm (brass-colored) 90153-SE0-003 1Paint cutting nut, 6 mm (yellow-tinted) 90361-SV4-003 3Washer-bolt, 6 x 12 mm (yellow-tinted) 93403-06012-08 1Washer-bolts, 6 x 16 mm (gray-colored) 93403-06016-05 7Flange bolts, 6 x 12 mm (yellow-tinted) 95701-06012-08 2Flange bolts, 6 x 25 mm (yellow-tinted) 95701-06025-08 4Flange bolt, 6 x 30 mm (yellow-tinted) 95701-06030-08 1
4. Remove the glove box frame and plastic cross-piece.
GLOVEBOXFRAME
Remove anddiscard this 5 mmwasher bolt.
Remove the glovebox frame (four bolts).
Placeprotectivetape on theblower unit.
Place protective tape(duct tape) on thepassenger’s side of theglove box opening.
Place protectivetape on thedriver’s side ofthe glove boxopening.
Move aside any vehicle harnessthat may be in the way, and use ahacksaw blade to carefully cutthrough the plastic cross-piece inthe areas shown. Remove anddiscard the plastic cross-piece andthe protective tape.
Release these two lock tabs, then remove therelay assembly from the glove box frame.
10. Install the A/C switch knob and the evaporator sensor.
Remove the blue tape securing theevaporator sensor 2P connectorto the vehicle harness.
HEATER UNITLOWER CASE
Insert the A/C switchbutton in the A/C switchhole, then push on thebutton until it clicksinto place.
With a smallflat-tip screwdriver,carefully pry outthe A/C switchhole cover anddiscard it.
FRONT
BLUETAPE
Remove the ashtray, then remove the self-tappingscrew. Remove the center console by pulling outon the cover to release the clips, then disconnectthe connectors and the illumination bulb.
With Cigarette Lighter/AshtrayWithout Cigarette Lighter/Ashtray
Remove the center console cover bypulling out on the cover to releasethe clips, then disconnect theaccessory power socket connector.
7
VEHICLEHARNESS
5
6Remove anddiscard thesensor holecover.
Insert the evaporatorsensor into thesensor hole, thenturn it clockwiseuntil it clicks into place.
Connect the evaporatorsensor to the sensorharness 2P connectoryou freed in step 5,then snap the connectorclip in the bracket onthe blower unit. 8
3
2
Apply protective tape to theheater control panel just belowthe A/C switch hole cover.
Secure the condenser line tothe receiver with one 6 x 25mm flange bolt (yellow-tinted),95701-06025-08. Torque thebolt to 10 N.m (7 lb-ft).
Apply refrigerantoil to both fittings onthe condenser line,then install the linebetween the receiverand condenser.
Secure the condenserline to the condenserwith one 6 x 25 mmflange bolt (yellow-tinted),95701-06025-08. Torquethe bolt to 10 N.m (7 lb-ft).
Apply refrigerant oilto its fitting, thenconnect the receiverline to the receiverwith one 6 x 25 mmflange bolt(yellow-tinted),95701-06025-08.Torque the bolt to10 N.m (7 lb-ft).
Install receiver line clip A(80381-S5A-A01) intothis square hole.
Install receiverline clip B(80387-SM4-A01)into this squarehole.
5
Carefully set the condenser fan assembly in place on the condenser fan mounts.
Install the compressor on the compressor bracket with the four 8 x 100 mm flange bolts (90023-P2A-000). Torque the bolts to 24 N.m (17lb-ft).
Secure the condenser fanassembly with two 6 x 16 mm washer-bolts (gray-colored),93403-06016-05. Torque the bolts to 10 N.m (7 lb-ft).
3
2
1
Install receiverline clip B(91548-S5A-003)into this squarehole.
Secure the condenser line tothe receiver with one 6 x 25 mmflange bolt (yellow-tinted),95701-06025-08. Torque the boltto N.m (7 lb-ft).
Secure the condenserline to the condenserwith one 6 x 25 mmflange bolt (yellow-tinted),95701-06025-08. Torquethe bolt to 10 N.m (7 lb-ft).
Apply refrigerant oil to itsfitting, then connect thereceiver line to the receiverwith one 6 x 25 mm flangebolt (yellow-tinted),95701-06025-08. Torquethe bolt to 10 N.m (7 lb-ft).
Install the compressor on the compressorbracket with the four 8 x 100 mm flangebolts (90023-P2A-000). Torque the boltsto 24 N.m (17 lb-ft).
Secure the condenser fanassembly with two 6 x 16 mmwasher-bolts (gray-colored),93403-06016-05. Torque thebolts to 10 N.m (7 lb-ft).
2Turn the adjusting bolt until the belt tensionreaches the “New Belt” tension.
Do not overtighten!
New Belt Tension: 830 to 980 N (85 to 100 kg)NOTE: After the A/C kit is installed andthe engine has run for 5 or more minutes(A/C performance test), readjust the belt tothe “Used Belt” tension.
Used Belt Tension: 390 to 540 N (40 to 55 kg).
Torque this bolt toits final torque of44 N.m (33 lb-ft).
Fit the belt tension gauge(T/N 07JGG-001010A)onto the A/C compressor belt.
Do not use any other gauge!
Torque this bolt to 44 N.m(33 lb-ft), then recheckthe belt tension.
Install the A/Ccompressor belt.Make sure the beltis properly alignedin the grooves ofthe pulleys.
Apply an initial torqueof 19 N.m (14 lb-ft) tothis bolt.
Torque this bolt toits final torque of44 N.m (33 lb-ft).
Apply an initial torqueof 19 N.m (14 lb-ft) tothis bolt.
Torque this bolt to 44 N.m(33 lb-ft), then recheckthe belt tension.
Torque this bolt to24 N.m (17 lb-ft).
New Belt Tension: 830 to 980 N (85 to 100 lbs.)NOTE: After the A/C kit is installed andthe engine has run for 5 or more minutes(A/C performance test), readjust the belt tothe "Used Belt" tension.
Slide the A/C suction line and receiver line B clamponto the mounting stud. Make sure that the throttle andheater cables are not caught or pinched by the bracket,then install a 6 mm paint-cutting nut (yellow-tinted),90361-SV4-003. Torque the nut to 10 N·m (7 lb-ft).
Connect the A/C suctionline and receiver line Bto the evaporator withone 6 x 30 mm flangebolt (yellow-tinted),95701-06030-08, andtwo 6 mm paint-cuttingnuts (yellow-tinted),90361-SV4-003. Torquethe bolt and nuts to10 N·m (7 lb-ft).
Push the brake booster vacuum hose towardthe engine, then feed the suction hose on theA/C suction line and receiver line B under it.
HEATERVALVE CABLE
THROTTLECABLE
1
4Reinstall the brakebooster hose clampinto the square holeon the bulkhead, thensnap A/C line B into it.
3
Reinstall the adjustingbolt, and turn it by handto get the proper belttension of 390 to 540 N(40 to 50 lbs.)Do not overtighten!
Install the suction hose bracket to the P/S hose bracket with a 6 x 12 mm washer-bolt (yellow-tinted), 93403-06012-08. Torque the bolt to 10 N.m (7 lb-ft).
P/S HOSEBRACKET
Apply refrigerant oil to its O-ring,then connect the suction line to thecompressor with the retained 6 mmflange nut. Torque the nut to 10 N.m(7 lb-ft).
Install the suction hose clamp onto the suction hosebracket, then secure the suction hose in the clamp.
Torque this fitting to 33 N.m (24 lb-ft). Make sure you use a second wrench to hold the other fitting.
Install the suction line bracket with two 6 x 16 mm washer-bolts (gray-colored), 93403-06016-05. Torque the bolts to 10 N.m (7 lb-ft).
Apply refrigerant oil to the suction hose O-ring, then loosely connect the suction hose to the suction line.
Remove and retain this 6 mmflange nut, then remove anddiscard the cap from thesuction side of the compressor.
1
3
5
7
4
2
6
3
Route the dischargehose below thecompressor clutchwire, and up to thecompressor.
COMPRESSORCLUTCH WIRE
SUCTION LINE
Apply refrigerant oil to its O-ring, thenconnect the discharge hose to thecondensor with a 6 x 25 mm flange bolt(yellow-tinted), 95701-06025-08. Torquethe nut to 10 N.m (7 lb-ft).
Remove and retain this 6 mmflange nut, then remove anddiscard the cap from thecompressor.
Apply refrigerant oil to its O-ring, then connect thedischarge hose to the compressor with the retained6 mm flange nut. Torque the nut to 10 N.m (7 lb-ft).
2
4
1
c
Torque this fitting to 33 N.m (24 lb-ft).Make sure you use a second wrenchto hold the other fitting.
Install the suction hose bracketto the P/S hose bracket witha 6 x 12 mm washer-bolt(yellow-tinted), 93403-06012-08.Torque the bolt to 10 N.m (7 lb-ft).
Apply refrigerant oil to is O-ring, thenconnect the suction line to the compressorwith the retained 6 mm flange nut. Torquethe nut to 10 N.m (7 lb-ft).
Apply refrigerant oil to its O-ring, thenconnect the discharge hose to thecondensor with a 6 x 25 mm flange bolt(yellow-tinted), 95701-06025-08. Torquethe nut to 10 N.m (7lb-ft).
Apply refrigerant oil to its O'ring, then connect thedischarge hose to the compressor with the retained6 mm flange nut. Torque the nut to 10 N.m (7 lb-ft).
• Relay assembly and glove box frame• Glove box• Passenger’s dashboard lower cover• Passenger’s kick panel• Center console cover, and reconnect the
accessory power socket or cigarette lighter.• Under-dash fuse/relay box• Driver’s dashboard lower cover• Front bumper and splash shield• Cruise control actuator; tighten the mounting
bolts to 10 N·m (7 lb-ft).• Power steering pressure switch connector• Brake fluid level switch connector• Resonator and air cleaner case• Reconnect the negative cable to the battery.• Check for battery voltage at the accessory
power socket (or cigarette lighter).
30. Do the idle learning procedure.
Whenever the battery or the ECM/PCM isdisconnected, the ECM/PCM must relearn theproper idle air control (IAC) values. To do this,follow this procedure exactly:• Start the engine, and turn off all accessories
(A/C, radio, defogger, etc.).• Warm the engine up to normal operating
temperatures (cooling fans come on twice),then let the engine idle for 10 minutes.
If the above procedure is not done correctly, theengine will have an erratic idle.
31. Evacuate the system.
The HFC-134a and compressor oil used in this A/C system are highly moisture absorbent. Afterinstalling the system, make sure you evacuate itfor at least 15 minutes.
NOTE:
• If low pressure does not reach more than700 mm Hg (27 in-Hg) in 15 minutes, there isprobably a leak in the system. Partially chargethe system, and check for leaks (see step 32).
• If the system is left open, the desiccant in thereceiver tank will become saturated withmoisture, requiring longer evacuation time.
32. Charge the system.• This system requires only the amount of HFC-
134a refrigerant shown below. If you overchargethe system, the engine and the A/C willmalfunction. Do not overcharge! Select theappropriate units of measure for your refrigerantcharging station.
500 to 550 grams
0.50 to 0.55 kilograms
1.1 to 1.2 pounds
17.6 to 19.4 ounces
• Do not add oil to the compressor; a newcompressor already contains enough oil for theentire A/C system. If you are replacingcompressor oil that has leaked out of thesystem, use only Sanden SP-10 oil.
• Using the wrong oil, or mixing different types ofoil, will result in abnormal compressor noise orseizure, or shortened compressor service life.These conditions are not covered by thewarranty policy.
33. Check for leaks.When testing for leaks, follow these guidelines:• Make sure you use a leak detector designed for
A/C systems that use HFC-134a.• To avoid false readings, do not use a tester
designed to detect Freon (CFC-12).• Because HFC-134a is heavier than air, always
check 360° around all fittings.• If you lose or damage an O-ring during A/C
installation, make sure you order the correctreplacement as listed here:
Part Name Part Number ApplicationO-ring, 8 mm 80873-ST7-000 Condenser line
34. Performance test the A/C system.Refer to Service Bulletin 96-012, Air ConditioningSystem Performance Test, filed under Accessoriesin the old Service Bulletin binder.
35. Readjust the A/C compressor belt to the “UsedBelt” tension: 390 to 540 N (40 to 55 lbs.).Refer to step 22 on page 20.