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

Background on the A/C Compressor Shaft Seal Leak

American Honda has identified a potential issue with the A/C compressor shaft seal in certain 2021 Honda Civic vehicles. This problem stems from new North American regulations that introduced different refrigerant and oil requirements. The new refrigerant and oil can cause the compressor shaft seal to swell, leading to abnormal wear and increased gaps around the seal. This ultimately results in refrigerant leaks.

To address this, American Honda has extended the warranty on the A/C compressor shaft seal from the original 3 years to 10 years from the vehicle's original date of purchase. This extended warranty has no mileage limitation. It's important to note that this warranty extension does not apply to vehicles that have been declared a total loss, sold for salvage, or have a branded title under any state's law.

Symptoms of an A/C Compressor Shaft Seal Leak

Owners of affected 2021 Honda Civic vehicles might notice the following indications of an A/C compressor shaft seal leak:

• Visible Oil Leaks: Oil may be present on the armature plate surface of the A/C compressor.
• Oil Transfer: If a felt washer from the compressor transfers oil to paper after 10 seconds, it indicates a leak.
• Refrigerant Leak: A calibrated leak detector can confirm a refrigerant leak around the compressor's snout.

Diagnosis for the 2021 Honda Civic A/C Compressor Shaft Seal Leak

Diagnosing the 2021 Honda Civic A/C compressor shaft seal leak involves a multi-step inspection process:

1. Visual Inspection: Technicians will first perform a visual check for oil on the armature plate surface of the A/C compressor. If no oil is visible, the center hub bolt and armature plate are removed for a more thorough inspection for oil.
2. Felt Washer Check: If no oil is found on the armature plate, the felt washer is removed and placed on a clean sheet of paper. Oil transfer to the paper within 10 seconds indicates a leak.
3. Leak Detector Test: A calibrated leak detector is used to check for leaks around the snout of the compressor. For the most accurate results, the leak detector should be used for at least five minutes, especially after the A/C compressor has not been running for some time, and with a higher vehicle engine temperature.

Repair Procedure Summary

If an A/C compressor shaft seal leak is confirmed, the repair involves replacing the compressor shaft seal. The general steps for this procedure, as outlined in Service Bulletin 23-039, are:

1. Refrigerant Recovery: Connect an A/C recover/recycle/recharge machine to the service ports and recover the A/C refrigerant.
2. Disconnection and Removal: Disconnect the discharge and suction hoses, immediately sealing the ports to prevent contamination. For Type R models, the charge air cooler inlet hose and A/C condenser fan shroud must also be removed. The A/C compressor is then removed from the vehicle.
3. Disassembly of Compressor: The center hub bolt, clutch, shims, felt washer, pulley outer C-ring, and pulley are carefully removed from the compressor.
4. Seal Removal: The old seal C-ring is removed. The bore and shaft are thoroughly cleaned with a lint-free cloth, avoiding compressed air.
5. Special Tool Application: For 1.5L engines, the side bracket is removed. Specialized press tools (such as 6CVC Seal Press 1.5L 07AAD-5AAA101 or 6CVC Seal Press 2.0L 07AAD-5BAA100) are used to break the compressor shaft seal loose and then extract it.
6. New Seal Installation: The bore and shaft are cleaned again. The new seal's outer surface, the seal guide, and the bore are lubricated with new POE compressor oil, taking care not to touch the center of the seal. The seal guide tool is inserted, followed by the new seal (metal side up). A press adapter tool is used to seat the new seal, ensuring it is about 5 mm below the top edge of the bore. The new seal C-ring is then inserted with the rounded side pointing down.
7. Final Seating: The press tool is used to fully seat the new seal, pressing it approximately 10 mm below the top edge of the bore until the C-clip is properly installed.
8. Reassembly and Recharge: The pulley and A/C compressor friction surfaces are cleaned. All components are reinstalled in reverse order, including the pulley, new pulley outer C-ring, new felt washer, shims, clutch plate, and a new clutch center flange bolt torqued to 17 N·m (13 lb-ft). The compressor is filled with POE compressor oil. The side bracket, compressor, and hoses (with new O-rings as needed) are reinstalled, followed by the drive belt and other removed parts. The A/C system is then recharged.
9. Post-Repair Check: The vehicle is run for ten minutes with the A/C on MAX COOL at 1,500-2,000 RPM. After turning the A/C off, a leak detector is used to recheck for leaks around the shaft seal, clutch, and O-ring areas. Finally, the undercover assembly and tire are reinstalled if no leaks are detected.

Required Tools or Parts

Performing the repair for the 2021 Honda Civic A/C compressor shaft seal leak requires specific parts and specialized tools:

Parts:

Description	Part Number	Quantity
Seal Set Assembly Kit (Contains: Bolt, Washer Set, Pulley C-Ring, Felt Washer, Shaft Seal, C-Ring Seal, Suction Port Plug, Discharge Port Plug)	38918-64A-318	1
O-Ring (1/2")	80872-SN7-003	1
O-Ring (5/8")	80871-SN7-003	1
POE Compressor Oil	38899-RLV-A01	1
RB100EV Oil	38899-64A-A02	1

Tools:

Part Name	Part Number	Quantity
A/C Compressor Seal Puller	07AAC-5AAA100	1
A/C Compressor Seal Guide	07AAG-5AAA101	1
A/C Compressor Seal Driver	07AAE-5AAA101	1
6CVC Seal Press (1.5L)	07AAD-5AAA101	1
6CVC Seal Press (2.0L)	07AAD-5BAA100	1

Additional tools include an A/C recover/recycle/recharge machine, a calibrated leak detector, lint-free cloths, a 19 mm wrench, a 36 mm wrench, a pick, a caliper, and Honda Brake Cleaner or equivalent.

Important Warnings for Owners

American Honda emphasizes that the procedures described in Service Bulletin 23-039 are intended for use only by skilled technicians with the proper tools, equipment, and training. These repairs should not be attempted by