Keeping Air Conditioning on a K-Swapped 1996-2000 Honda Civic (EK)

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Time 3-5 hours plus professional A/C charge

Level Difficult

Steps 14

Done by

In progress You stopped at step of 14.

Caution

Releasing refrigerant to the air is illegal in many places and can cause frostbite; have the system recovered and charged by a licensed technician.
Disconnect the battery before soldering into ECU or connector wiring.
Not listed for ABS-equipped or right-hand-drive EK Civics.

Introduction

A K-series compressor sits in a different spot from a D or B-series one, so the factory EK A/C lines will not reach after a K-swap. Hybrid Racing's kit supplies four new lines to connect a K20A/A2/A3/Z1 compressor to a 1996-2000 Civic condenser and the factory evaporator lines, plus a relay to drive the compressor clutch from the Civic's A/C request. It also works on a K24 if one of those compressors is used. Hybrid Racing lists it for left-hand-drive cars only and not for ABS-equipped models. If you delete power steering you need the K20A3 (2002-2005 Civic Si) pulley setup and belt; with power steering kept, a stock K20A/A2/Z1 belt is used. The system must be professionally evacuated before work and charged afterwards. Adapted from a community writeup by Hybrid Racing on guides.hybrid-racing.com (https://guides.hybrid-racing.com/Guide/96-00+Civic+K-Swap+AC+Line+Install+Guide/46).

Procedure

14 steps

Step 1: Have the system recovered

If the car still holds refrigerant, have a licensed A/C shop recover it before opening any line.
Step 2: Remove the lines that will be replaced

Remove the factory A/C lines that the kit replaces (the kit instructions mark these), leaving the evaporator-side lines in place.
Step 3: Keep the three OEM lines

The lines that stay are Honda 80341-S01-A01, 80342-S01-A01 and 80343-S01-A01. If your car is missing any of them, buy them before starting.
Step 4: Install line A

Fit line A starting at the firewall end, using the correct-size O-ring lubricated with refrigerant-compatible oil.
Step 5: Install line B

Fit line B to the end of line A with an O-ring in place, and connect its other end to the compressor.
Step 6: Mount the condenser

Install the 1996-2000 Civic condenser with its rubber bushings and pressure switch. Secure it at the top with the kit bracket; if you cut off the lower tabs, use replacement lower brackets. Check what your kit includes, as current product listings differ on whether brackets are supplied.
Step 7: Install line D

Connect line D from the top of the condenser to the compressor.
Step 8: Install line C

Line C runs from the bottom of the condenser to the evaporator line. Bolt it to the condenser without damaging the O-ring, run it alongside the OEM line to the evaporator connection and secure it with a 10 mm bolt.
Step 9: Check line clearance

Make sure every line is clamped and cannot touch the accessory belt, pulleys, exhaust or sharp edges when the engine rocks.
Step 10: Wire the compressor relay (1996-1998)

On 1996-1998 Civics, Hybrid Racing wires the relay as: pin 85 to a 12 V feed live in RUN, pin 87 to ground, pin 30 to connector C131 pin 19 (black/red), pin 86 to C131 pin 7 (blue/red).
Step 11: Wire the compressor relay (1999-2000)

On 1999-2000 Civics: red wire (pin 85) to a 12 V feed live in RUN, blue (pin 87) to ground, yellow (pin 30) to ECU terminal A17 (ACC, black/red) and green (pin 86) to ECU terminal A27 (ACS, blue/red). Solder and heat-shrink every joint.
Step 12: Extend the compressor clutch wire

Find the single-pin compressor connector on the driver side and extend it to the new compressor. Reusing the connector from the old compressor makes the plug mate correctly.
Step 13: Wire the fan and pressure switch

Wire the condenser fan and the condenser pressure switch so the compressor cycles on and off. Hybrid Racing's online guide does not list these connections, but its product page says the kit's instructions cover them. Follow the paper instructions that came with your kit, or the factory wiring diagram for your car.
Step 14: Evacuate, charge and test

Take the car to a certified A/C technician to vacuum, leak-test and charge the system. Ask for a pressure check before you leave, as a pinched O-ring is the most likely leak.