2021 Honda Civic A/C Compressor Shaft Seal Leak Warranty

Honda has released Service Bulletin 23-039, Version 5, dated June 19, 2024, to address a potential A/C compressor shaft seal leak in certain 2021 Honda Civic models. This bulletin supersedes a previous version, 23-039 dated January 18, 2024, to provide updated information. The core issue is related to new North American regulations concerning A/C refrigerant and oil, which can cause the compressor shaft seal to swell and wear abnormally, leading to refrigerant leaks.

To provide relief for affected owners, American Honda is extending the warranty on the A/C compressor shaft seal. The coverage is now 10 years from the original date of purchase, with unlimited mileage, a significant increase from the original 3-year warranty.

Symptoms of an A/C Compressor Shaft Seal Leak

Owners of affected 2021 Honda Civic vehicles might notice a decrease in the effectiveness of their air conditioning system. This is typically due to a loss of refrigerant caused by the leaking compressor shaft seal. While no specific dashboard warning lights are mentioned, a noticeable reduction in cooling performance is a key indicator.

Diagnosis and Inspection

To determine if your 2021 Honda Civic is experiencing a Honda Civic A/C compressor shaft seal leak, a Honda technician will perform a detailed inspection. This involves several steps:

1. Initial Visual Check: The technician will remove the right-front tire and engine undercover to gain access to the A/C compressor.
2. Oil Presence Check: They will inspect the armature plate surface of the compressor for any signs of oil. If oil is present, it indicates a leak.
3. Felt Washer Examination: If no oil is immediately visible, the felt washer from the compressor will be removed and placed on paper. If oil transfers to the paper within 10 seconds, a leak is confirmed.
4. Leak Detector Test: A calibrated leak detector will be used around the compressor snout for at least five minutes to detect any refrigerant leaks. Running the vehicle for ten minutes and re-testing may be necessary for accurate results.

If no oil or leak is found after these checks, the components will be reassembled, and the vehicle will be run for ten minutes before a final leak check is performed. If a leak is detected at any point, the repair procedure will be initiated.

Repair Procedure Summary

The repair for the Honda Civic A/C compressor shaft seal leak involves a comprehensive process to replace the faulty seal. Technicians are advised to wear safety glasses and rubber gloves due to the presence of fluids. The general steps include:

1. A/C System Preparation: Connecting an A/C recover/recycle/recharge machine to the high-pressure and low-pressure service ports, then recovering the A/C refrigerant.
2. Component Disconnection: Disconnecting the discharge and suction hoses, immediately sealing the ports to prevent contamination. For Civic Type R models, the charge air cooler inlet hose and A/C condenser fan shroud must also be removed.
3. Compressor Removal: Removing the A/C compressor from the vehicle.
4. Disassembly: Removing the center hub bolt, clutch, felt washer, outer pulley C-ring, and pulley. The old seal C-ring is then removed.
5. Cleaning: Thoroughly cleaning the compressor bore and shaft with a lint-free cloth, avoiding compressed air to prevent debris from entering the system.
6. Seal Extraction: Using specialized tools, including a press tool and extractor tool, to carefully break loose and extract the old compressor shaft seal.
7. New Seal Installation: Inspecting the compressor shaft bore for damage, lubricating the new seal and seal guide with new POE compressor oil, and then installing the new seal using the seal guide tool and press adapter. The new seal C-ring is then inserted.
8. Reassembly: Reinstalling the pulley, new pulley outer C-ring, new felt washer, clutch plate, shims, and a new clutch center flange bolt (torqued to 17 N·m or 13 lb-ft). The compressor is filled with one can of POE compressor oil.
9. Final Steps: Mounting the side bracket, installing the compressor, connecting the suction and discharge hoses (replacing O-rings as needed), and reinstalling the drive belt and other removed parts.
10. System Recharge and Test: Recharging the A/C system, setting it to MAX COOL, and running the vehicle for ten minutes at 1,500-2,000 RPM. A final leak detector check is performed around the shaft seal, clutch, and O-ring areas with the A/C off before installing the undercover and tire.

Required Tools and Parts

To perform this repair, specific parts and specialized tools are necessary:

• Parts:
  • Seal Set Assembly Kit: 38918-64A-318
  • O-Ring (1/2"): 80872-SN7-003
  • O-Ring (5/8"): 80871-SN7-003
  • RB100EV Oil: 38899-64A-A02
• Special Tools:
  • A/C Compressor Seal Puller: 07AAC-5AAA100
  • A/C Compressor Seal Guide: 07AAG-5AAA101
  • A/C Compressor Seal Driver: 07AAE-5AAA101
  • 6CVC Seal Press (1.5L): 07AAD-5AAA101
  • 6CVC Seal Press (2.0L): 07AAD-5BAA100

These tools were auto-shipped to dealers in December 2022. For support or replacements, the Special Tools Hotline can be contacted at (800) 346-6327.

Warranty Claim Information

For warranty claims related to the A/C compressor shaft seal replacement, dealers will use the following codes:

• Operation Number: 6141D4
• Description: AC compressor seal replacement (includes 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

Important Warnings for Owners

• Eligibility: This warranty extension does not apply to any vehicle that has 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.
• DIY Repairs: The procedures outlined in Service Bulletin 23-039 are intended for skilled technicians with proper tools, equipment, and training. These repairs should not be attempted by