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

Honda has released Service Bulletin 23-039, Version 3, dated September 28, 2023, which supersedes the previous bulletin dated June 15, 2023. This bulletin addresses a potential A/C compressor shaft seal leak in certain 2021 Honda Civic vehicles and extends the warranty coverage for this specific issue. The Honda Civic A/C compressor leak is a known concern that Honda is proactively addressing.

Symptoms of an A/C Compressor Shaft Seal Leak

The Honda Civic A/C compressor leak is primarily caused by a new North America regulation introducing a different refrigerant and oil requirement. This new formulation can lead to swelling and abnormal wear of the A/C compressor shaft seal. Over time, this wear can increase the seal gaps, allowing refrigerant to leak out. Owners might notice reduced air conditioning performance or a complete loss of cooling capacity.

Important Warnings for Owners

Honda has specified a crucial condition regarding this warranty extension:

"This warranty extension will not apply to any vehicle that has ever been declared a total loss or sold for salvage by a financial institution or insurer, or has a branded or similar title under any state's law."

Owners will be notified by Honda about this campaign. It is recommended to check your vehicle's VIN status with a Honda dealer to confirm eligibility.

Diagnosis of the A/C Compressor Leak

Technicians will follow a detailed inspection procedure to confirm a Honda Civic A/C compressor leak. This involves:

• Visual Inspection: Checking for oil on the compressor's clutch area or hub/armature plate while the compressor is still in the vehicle. If oil is present, the repair procedure is initiated.
• Felt Washer Test: Removing the felt washer from the compressor and placing it on clean paper. If oil transfers to the paper within 10 seconds, a leak is indicated.
• Calibrated Sniffer Test: Using a calibrated sniffer to detect refrigerant leaks around the compressor's snout. This test is performed for at least five minutes, and a longer period since the A/C compressor was last run, or a higher vehicle temperature, can improve detection accuracy.

If no leak or oil is detected after these steps, the technician will reassemble the components, run the vehicle for ten minutes, and repeat the sniffer test. If still no leak is found, other A/C components will be checked.

Repair Procedure Summary

If a Honda Civic A/C compressor leak is confirmed, the repair involves replacing the A/C compressor shaft seal. The general steps include:

1. Refrigerant Recovery: Connecting an A/C recover/recycle/recharge machine to the high-pressure and low-pressure service ports to recover the refrigerant.
2. Component Removal: Disconnecting hoses, and removing the A/C compressor, clutch, felt washer, pulley, and seal C-rings. For Civic Type R models, additional components like the change air cooler inlet hose and A/C condenser fan shroud may need removal.
3. Seal Extraction: Using specialized press and extractor tools to carefully remove the old compressor shaft seal. The bore and shaft are thoroughly cleaned with a lint-free cloth, avoiding compressed air.
4. New Seal Installation: Lubricating the new seal and installing it using a seal guide tool, press adapter tool, and press tool. The new seal C-ring must be inserted with the rounded edge facing down.
5. Reassembly and Recharge: Reinstalling all removed components, performing a vacuum inspection, and then filling the A/C system with the correct amount of A/C refrigerant and POE compressor oil.
6. Final Leak Check: Running the A/C system on MAX COOL for ten minutes at 1,500-2,000 RPM, followed by a final leak check with a calibrated sniffer around the clutch and O-ring areas.

Required Tools and Parts

To perform this repair, specific parts and special tools are required:

• Parts:
  • Seal Set Assembly Kit: Part Number 38918-64A-318
  • 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: This oil is being phased out and replaced by RB100EV Oil, Part Number 38899-64A-A02)
• Special Tools:
  • 6CVC Seal Replacement Kit: Part Number 07AAC-5AAA1Z0 (Auto-shipped to dealers in December 2022. Dealers should contact the Special Tools Hotline at (800) 346-6327 if not received).
  • Press Tool (1.5T): Part Number 07AAD-5AAA101
  • Press Tool (2.0/2.0T): Part Number 07AAD-5BAA100

Warranty Information

Honda is extending the warranty for the A/C compressor shaft seal to 10 years from the original date of purchase, with no mileage limitation. This repair is covered under Operation Number 6141D4, with a flat rate time of 2.1 hours. The Defect Code is 6A500, the Symptom Code is RE800, and the Template ID is A23039A. The Failed Part Number associated with this issue is 38810-5BA-A03.

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Source: NHTSA ID 10243738