2021 Honda Civic A/C Compressor Seal Leak TSB 23-039

Owners of 2016-2021 Honda Civic and Civic Type R vehicles may experience an A/C compressor shaft seal leak. This issue, detailed in Honda Service Bulletin 23-039, is attributed to new North American refrigerant and oil regulations. The updated refrigerant and oil can cause the compressor shaft seal to swell, leading to abnormal wear, increased seal gaps, and ultimately, refrigerant leakage.

To address this, American Honda is extending the warranty on the A/C compressor shaft seal from the original 3 years to 10 years from the original date of purchase, with no mileage limitation. This bulletin, version 2, supersedes the previous bulletin 23-039 dated May 19, 2023, with minor revisions to the repair procedure.

Why This Matters

The A/C compressor shaft seal is a critical component of your vehicle's air conditioning system. If it leaks, your A/C system will lose refrigerant, leading to reduced cooling performance or complete failure of the air conditioning. The extended warranty provides significant coverage for owners affected by this specific issue, ensuring repairs are covered for a longer period.

Symptoms of an A/C Compressor Shaft Seal Leak

The primary symptom of this issue is a refrigerant leak from the A/C compressor shaft seal. Owners might notice a decrease in A/C cooling efficiency or the A/C system blowing warm air. Technicians will look for visual signs of oil around the compressor clutch area or detect refrigerant leaks using a specialized sniffer tool.

Diagnosis and Trigger Conditions

Diagnosis involves a multi-step inspection process. Technicians will first visually inspect the compressor clutch area for any signs of oil. If no oil is present, a calibrated sniffer tool will be used to detect refrigerant leaks around the compressor's snout. For accurate results, the sniffer test should be performed for at least five minutes, and a higher vehicle temperature can improve detection.

Repair Procedure Summary

The repair procedure outlined in Service Bulletin 23-039 is comprehensive, involving the removal and reinstallation of several components to access and replace the A/C compressor shaft seal. Key steps include:

1. Preparation: Removing the right front tire and undercover assembly to access the compressor. The drive belt is also removed.
2. Initial Inspection: Checking for oil on the compressor clutch area and hub/armature plate. If oil is found, or if a felt washer test shows oil transfer, the repair proceeds.
3. A/C System Recovery: Connecting an A/C recover/recycle/recharge machine to recover refrigerant.
4. Compressor Removal: Disconnecting hoses and removing the A/C compressor from the vehicle. For Type R models, the charge air cooler inlet hose and A/C condenser fan shroud are also removed.
5. Seal Disassembly: Removing the clutch, shims, felt washer, pulley, and both the outer pulley C-ring and seal C-ring.
6. Seal Extraction: Using specialized press and extractor tools to carefully break loose and remove the old compressor shaft seal.
7. Cleaning and Lubrication: Thoroughly cleaning the compressor shaft bore and lubricating the new seal, seal guide, and bore with new POE compressor oil.
8. New Seal Installation: Inserting the new seal onto the seal guide tool, ensuring it is directional with the metal side upwards, and pressing it into place using a press adapter tool. The new seal C-ring is then installed with the rounded edge facing down.
9. Reassembly: Reinstalling all components in reverse order, including the pulley, felt washer, clutch plate, and spacers. The clutch center flange bolt is tightened to 17 N·m (13 lb-ft).
10. A/C System Recharge and Test: Filling the compressor with POE compressor oil, performing a vacuum inspection, and recharging the A/C system with refrigerant. The system is then run at MAX COOL for ten minutes at 1,500-2,000 RPM, followed by a final sniffer test around the shaft seal and O-ring areas to confirm no leaks.

Required Tools or Parts

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

• 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: RB100EV Oil, Part Number 38899-64A-A02, will replace POE Compressor Oil)
• 6CVC Seal Replacement Kit: Part Number 07AAC-5AAA1Z0 (auto-shipped to dealers in December 2022)
• Press Tools: Specific tools for 1.5T (07AAD-5AAA101), 2.0 (07AAD-5BAA100), and 2.0T (07AAD-5BAA100) engines.

Important Warnings

• Cleaning: Do not use compressed air when cleaning the bore and shaft. The bore must be very clean to prevent debris from entering the compressor, which could lead to future failure.
• Tool Use: When breaking the compressor shaft seal loose, turn the handle of the press tool no more than 3/4 turn (270°). Turning it further can damage the tool and the seal, making removal difficult.
• Seal Handling: Avoid touching the center of the new seal with bare hands to prevent cross-contamination of the A/C refrigerant system.

Warranty Information

Honda is extending the warranty on the A/C compressor shaft seal for affected 2016-2021 Civic and Civic Type R vehicles to 10 years from the original date of purchase, with no mileage limitation. The warranty claim information includes Operation Number 6141D4, Flat Rate Time 2.1 hours, Defect Code 6A500, Symptom Code RE800, Template ID A23039A, and Failed Part Number 38810-5BA-A03.

Customer Notification

Owners of affected vehicles will receive a notification regarding this campaign. Honda advises owners to perform an iN VIN status inquiry to confirm their vehicle's eligibility for this warranty extension and repair.

Owner Action

If you own a 2016-2021 Honda Civic or Civic Type R and suspect an 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 the necessary inspection and, if directed, replace the compressor shaft seal under the extended warranty.

NHTSA ID: 10237948