2021 Honda Civic A/C Compressor Shaft Seal Leak Warranty Extension

Background to the Honda Civic A/C Compressor Shaft Seal Leak

American Honda has identified a potential issue with the A/C compressor shaft seal in certain 2021 Civic models. This problem stems from a new North America regulation that mandates a different refrigerant and oil. The new substances can cause the compressor shaft seal to swell and wear abnormally, leading to refrigerant leaks.

To address this, Honda has extended the warranty on the A/C compressor shaft seal from the original 3 years to 10 years from the date of purchase, with no mileage limitation. This warranty extension is documented under Service Bulletin 23-039.

Important Warnings for Owners

Owners should be aware of specific instructions related to this repair to ensure proper function and prevent future issues:

• Do not use compressed air when cleaning the compressor bore and shaft. This can introduce debris, leading to future failure of the seal.
• Avoid touching the center of the new seal with bare hands to prevent cross-contamination of the A/C refrigerant system.

Symptoms and Diagnosis

The primary symptom of this issue is a refrigerant leak from the A/C compressor shaft seal. Technicians will perform a visual inspection for oil on the clutch area of the compressor. If oil is present, it indicates a leak.

Further diagnostic steps include:

• Removing the hub/armature plate and felt washer to inspect for oil saturation.
• Using a calibrated sniffer tool to detect refrigerant leaks around the compressor snout. For accurate results, the sniffer should be used for at least five minutes, and a higher vehicle temperature can improve detection.

Repair Procedure Summary

The repair involves replacing the A/C compressor shaft seal. The general procedure, as outlined in Service Bulletin 23-039, includes:

1. Preparation: Removing the right front tire, undercover assembly, and the drive belt. Special care is taken when removing the drive belt due to its hydraulic auto-tensioner.
2. Inspection: Thoroughly inspecting for oil on the compressor's clutch area, hub/armature plate, and felt washer.
3. A/C System Evacuation: Connecting an A/C recover/recycle/recharge machine to evacuate the refrigerant from the system.
4. Component Removal: Disconnecting discharge and suction hoses, removing the A/C compressor, clutch center flange bolt, clutch, shims, felt washer, pulley outer C-ring, and pulley.
5. Seal Removal: Cleaning the bore and shaft with a lint-free cloth. Using specialized tools like a press tool, press adapter tool, cylinder tool, and extractor tool to carefully remove the old shaft seal. Technicians are instructed not to use compressed air during cleaning.
6. New Seal Installation: Inspecting the compressor shaft bore and seal guide for damage. Lubricating the new seal's outer surface, seal guide, and bore with new POE compressor oil. The new seal is directional and must be placed with the metal side upwards. The new seal is installed using the press adapter tool and press tool, ensuring it is seated correctly about 5 mm below the bore.
7. Reassembly: Installing the new seal C-ring (part of kit 38918-64A-318) with the rounded edge facing down. Reinstalling the pulley, new pulley outer C-ring, new felt washer, clutch plate, shims, and clutch center flange bolt. The clutch center flange bolt is tightened to 17 N·m (13 lb-ft). The A/C compressor bolts are tightened to 22 N·m (16 lb-ft), and the discharge/suction hose bolts/nuts to 9.8 N·m (7.2 lb-ft).
8. A/C System Recharge: Filling the compressor with POE compressor oil and recharging the A/C system with the correct amount of refrigerant.
9. Final Leak Check: Running the vehicle for ten minutes with the A/C system set to MAX COOL and the engine at 1,500-2,000 RPM. A calibrated sniffer is used to check for leaks around the shaft seal. If a leak is detected after a second seal replacement, the entire compressor assembly must be replaced.

Required Tools or Parts

To perform this repair, specific parts and a special tool kit are necessary:

• Seal Set Assembly Kit: Part Number 38918-64A-318 (Contains Bolt, Washer Set, Pulley C-Ring, Felt Washer, Shaft Seal, C-Ring Seal, Suction Port Plug, Discharge Port Plug)
• O-Ring (1/2"): Part Number 80872-SN7-003
• O-Ring (5/8"): Part Number 80871-SN7-003
• POE Compressor Oil: Part Number 38899-RLV-A01 (Note: POE Compressor Oil will be phased out and replaced by RB100EV Oil, Part Number 38899-64A-A02)
• 6CVC Seal Replacement Kit: Part Number 07AAC-5AAA1Z0 (This special tool kit was auto-shipped to dealers in December 2022. Dealers who have not received it should contact the Special Tools Hotline at (800) 346-6327).

Warranty Claim Information

For warranty claims related to this Honda Civic A/C compressor shaft seal leak, technicians should use the following information:

• Operation Number: 6141D4 (AC compressor seal replacement, including inspection, evacuate, and recharge)
• Flat Rate Time: 2.1 hours
• Defect Code: 6A500
• Symptom Code: RE800
• Template ID: A23039A
• Failed Part Number: 38810-5BA-A03

What Owners Should Do

Owners of affected 2021 Honda Civic vehicles will be sent a notification regarding this warranty extension campaign. If you suspect your vehicle is experiencing a Honda Civic A/C compressor shaft seal leak or if your A/C system is not performing correctly, contact an authorized Honda automobile dealer. They can perform a VIN status inquiry to confirm your vehicle's eligibility and schedule the necessary inspection and repair.

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Source: NHTSA ID: 10237036