A/C - System Is Inoperative
10-037September 18, 2010
Applies To:
2004 TSX - ALL
A/C System Does Not Work
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 and coil, and all other A/C system parts. Replace all parts that are internally contaminated or that fail the service manual test.
TOOL INFORMATION
A/C Clutch Holder:
Robinair 10204, Kent-Moore J37872,
Honda tool and equipment KMT-J33939,
or commercially available
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
The normal warranty applies.
Failed Part: P/N 38810-RBB-AO1
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 04-08 TSX Service Manual, or view them online:
^ Refrigerant Recovery/Recharging
^ Battery Disconnection/Reconnection
^ Battery Removal/Installation
^ Bulkhead Cover Removal/Installation
^ Splash Shield Removal/Installation
^ Drive Belt Removal/Installation
^ A/C Compressor Replacement
^ A/C Condenser Replacement
^ A/C Compressor Clutch Check
^ A/C Compressor Clutch Overhaul
^ Blower Unit Removal/Installation
^ Evaporator Core Replacement
^ Expansion Valve Replacement
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 NC 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 line using a new 0-ring, then continue with normal troubleshooting.
6. Remove the nut, then remove the suction line 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 A/C 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 bulkhead cover.
8. Make sure the ignition switch is in LOCK (0), then remove the battery and the battery box.
9. Remove the clips, then remove the intake air cover and the intake air duct.
10. Remove the A/C condensor fan shroud (three bolts):
^ Disconnect the A/C compressor clutch connector.
^ Disconnect the A/C condensor fan connector.
^ Remove the wire harness clip.
^ Remove the hose from the coolant reservoir.
NOTE:
Be careful not to damage the radiator fins.
11. Remove the radiator upper mount brackets (two bolts).
12. Remove the bolt, then disconnect the receiver line from the A/C condenser.
13. Remove the A/C condenser upper mount brackets (two bolts).
14. Remove the bolt, then disconnect the discharge line from the A/C condenser.
15. Remove the A/C condenser by lifting it up, being careful not to damage the fins on the radiator and the A/C condenser.
16. 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 17.
^ If no metal particles or debris is found, go to step 18.
17. 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.
18. Remove the cap with 0-rings, the filter, and the dessiccant 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 repair procedure B
REPAIR PROCEDURE A
1. To provide sufficient clearance for removing the A/C compressor, use a piece of wire or a wire tie to pull the radiator forward against the bulkhead.
2. Remove the drive belt.
3. Remove the splash shield.
4. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins.
5. Check the A/C compressor clutch as described in the service manual.
6. 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.
7. 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.
8. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge and suction lines with new 0-rings, then torque the line nut and the bolt 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.
9. 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.
10. Lower the A/C condenser into position, then reconnect the discharge line (with a new 0-ring) to the top of the A/C condenser. Torque the nuts to 9.8 N.m (7.2 lb-ft).
11. Reinstall the A/C condenser upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft).
12. Reinstall the radiator upper mount brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft).
13. Reconnect the receiver pipe to the bottom of the condenser, then torque the bolts to 9.8 N.m (7.2 lb-ft).
14. Reinstall the A/C condenser fan shroud and the coolant reservoir. Torque the fan shroud bolts to 9.8 N.m (7.2 lb-ft).
15. Reinstall the A/C compressor/condenser fan harness to the fan shroud, then reconnect the connector.
16. Reinstall the intake air duct and the intake air cover.
17. Reinstall the battery box and the battery.
18. Reinstall the bulkhead cover and the splash shield.
19. Reconnect the battery cables to the battery, then do the battery reconnection procedure.
20. 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
1. To provide sufficient clearance for removing the A/C compressor, use a piece of wire or a wire tie to pull the radiator forward against the bulkhead.
2. Remove the drive belt.
3. Remove the splash shield.
4. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins.
5. Check the A/C compressor clutch as described in the service manual.
6. 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.
7. 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.
8. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge and suction lines with new 0-rings, then torque the line nut and the bolt 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.
9. 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.
10. Install a new A/C condenser into position, then install a new discharge line and new 0-ring to the top of the A/C condenser. Torque the nuts to 9.8 N.m (7.2 lb-ft).
11. Reinstall the A/C condenser upper mount brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft).
12. Reinstall the radiator upper mount brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft).
13. Reconnect the receiver pipe to the bottom of the condenser, and torque the bolts to 9.8 N.m (7.2 lb-ft).
14. Reinstall the A/C condenser fan shroud and the coolant reservoir. Torque the fan shroud bolts to 9.8 N.m (7.2 lb-ft).
15. Reinstall the A/C compressor/condenser fan harness to the fan shroud.
16. Reinstall the intake air duct and the intake air cover.
17. Reinstall the battery box and the battery.
18. Reinstall the bulkhead cover and the splash shield.
19. Reconnect the battery cables to the battery, then do the battery reconnection procedure.
20. 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 C
1. To provide sufficient clearance for removing the A/C compressor, use a piece of wire or a wire tie to pull the radiator forward against the bulkhead.
2. Remove the drive belt.
3. Remove the splash shield.
4. Remove the A/C line/suction hose assembly, the receiver line, and the discharge hose.
5. Disconnect the connector, then remove the NC compressor (four bolts). Be careful not to damage the radiator fins.
6. Remove the passenger's dashboard lower cover.
7. Remove the glove box.
8. Remove the passenger's kick panel.
9. Remove the wire harness connector, the wire harness clip, and the bolt. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, then remove it.
10. Remove the blower unit:
^ Disconnect the connectors.
^ Remove the wire harness clips.
11. Disconnect the connector from the power transistor, then remove the wire harness clips, the self-tapping screws, and the expansion valve cover.
12. Carefully pull out the evaporator core and the plate.
13. Remove the bolts from the expansion valve.
14. Install a new expansion valve on the new evaporator, and torque the bolts to 3.2 N.m (2.3 lb-ft).
15. Reinstall the evaporator core and the plate.
16. Install the new suction line and new receiver line to the new expansion valve. Reinstall the expansion valve cover. Then reconnect the connector to the power transistor.
17. Reinstall the blower unit and reconnect the connectors, the kick panel, the glove box, and the passenger's dashboard lower cover.
18. 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.
19. Check the A/C compressor clutch as described in the service manual.
20. 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.
21. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the new discharge line and suction line with new 0-rings, then torque the line nut and the bolt 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.
22. Install the new A/C condenser into position then connect the new discharge line and the new receiver line with new 0-rings to the A/C condenser. Torque the bolts to 9.8 N.m (7.2 lb-ft).
23. Reinstall the A/C condenser upper mount brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft).
24. Reinstall the radiator upper mount brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft).
25. Reinstall the A/C condenser fan shroud and the coolant reservoir. Torque the fan shroud bolts to 9.8 N.m (7.2 lb-ft).
26. Reconnect the fan motor connector.
27. Reinstall the A/C compressor/condenser fan harness to the fan shroud.
28. Reinstall the intake air duct and the intake air cover.
29. Reinstall the battery box and the battery.
30. Reinstall the bulkhead cover and the splash shield.
31. Reconnect the battery cables to the battery, then do the battery reconnection procedure.
32. 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.
NOTE:
A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system.