HVAC System - Automatic: Removal & Installation Honda Accord VI

REMOVAL & INSTALLATION

Remove glove box. Remove glove box frame. Remove filter lid from evaporator. Pull out lower A/C filter assembly, then upper A/C filter assembly, in order. (Scheme 8) Remove filter from housing. To install, reverse removal procedure. Ensure no air leaks from evaporator.

Scheme 8

Access lower passenger side of instrument panel. Remove 3 blower motor attaching screws from blower unit. Disconnect blower motor connector. Remove blower motor from blower unit. To install, reverse removal procedure.

Disconnect negative battery cable. Use small, flat-tipped screwdriver to remove clock/hazard switch from center panel. Remove screws from beneath center panel and from inside clock opening. Firmly pull on center panel to disengage clips. Disconnect climate control unit electrical connectors. Remove screws attaching climate control unit to center panel. Remove climate control panel. To install, reverse removal procedures.

Removal & Installation (2.3L)

1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.
2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.
3. Disconnect the negative cable from the battery.
4. Recover the refrigerant with a recovery/recycling/charging station.
5. Loosen the A/C compressor belt.
6. Remove the nuts, then disconnect the suction line (A) and discharge line (B) from the compressor. (Scheme 9) Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
7. Disconnect the «compressor clutch»(ref-35216-S41477931282004021900000) connector (A), then remove the mounting bolts and the compressor (B). (Scheme 10)
8. Remove the bolts, the suction service valve (A) and the O-ring (B) from the compressor. (Scheme 11)
9. If necessary, remove the mounting bolts, mounting nuts and the compressor bracket. (Scheme 12)
10. Install the compressor in the reverse order of removal, and note these items: If you're installing a new compressor, you must calculate the amount of refrigerant oil to be removed from it. see scheme 1 Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage. Use refrigerant oil (DENSO ND-OIL 8) for HFC-134a DENSO piston type compressors only. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint. If the refrigerant oil contacts the paint, wash it off immediately. Adjust the A/C compressor belt. Charge the system. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Removal & Installation (3.0L)

1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.
2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.
3. Disconnect the negative cable from the battery.
4. Recover the refrigerant with a recovery/recycling/charging station.
5. Remove the alternator. (Scheme 13)
6. Remove the compressor clutch connector (A) from the condenser fan shroud (B), then disconnect the «compressor clutch»(ref-35216-S41477931282004021900000) connector. (Scheme 14) Disconnect the condenser fan connector (C), then remove the wire harness clips (D) from the condenser fan shroud. Remove the cruise control actuator cable (E) from the clamp. Loosen the lower mounting bolt, then remove the upper mounting bolts and the condenser fan shroud. Be careful not to damage the radiator fins when removing the condenser fan shroud.
7. Remove the bolt and the nut, then disconnect the suction (A) and discharge (B) lines from the compressor. (Scheme 15) Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
8. Remove the mounting bolts and the compressor. (Scheme 16) Be careful not to damage the radiator fins when removing the compressor.
9. Remove the bolts, the suction service valve (A) and the O-ring (B) from the compressor. (Scheme 11)
10. If necessary, remove the mounting bolts and the compressor bracket. (Scheme 17)
11. Install the compressor in the reverse order of removal, and note these items: If you're installing a new compressor, you must calculate the amount of refrigerant oil to be removed from it. see scheme 1 Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage. Use refrigerant oil (DENSO ND-OIL 8) for HFC-134a DENSO piston type compressor only. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Be careful not to damage the radiator fins when installing the compressor and the condenser fan shroud. Charge the system. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Remove the compressor. See «COMPRESSOR»(ref-35216-S38622179152001010900000). Remove the center bolt while holding the pressure plate with a commercially available A/C clutch holder. (Scheme 18)
2. Remove the pressure plate (A) and shim(s) (B), taking care not to lose the shim(s). (Scheme 19) If the clutch needs adjustment, increase or decrease the number and thickness of shims as nesessary, then reinstall the pressure plate, and recheck its clearance.
3. If you are replacing the field coil, remove the snap ring (A) with snap ring pliers, then remove the pulley (B). Be careful not to damage the pulley and compressor. (Scheme 20)
4. Remove the screw from the field coil ground terminal (A). Remove the snap ring (B) with snap ring pliers, then remove the field coil (C). (Scheme 21) Be careful not to damage the field coil and compressor.
5. Reassemble the clutch in the reverse order of disassembly, and note these items: Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the compressor. Clean the pulley and compressor sliding surfaces with contact cleaner or other non-petroleum solvent. Install new snap rings, note the installation direction, and make sure they are fully seated in the groove. Make sure that the pulley turns smoothly after it's reassembled. Route and clamp the wires properly or they can be damaged by the pulley.

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove relief valve and "O" ring from top of compressor. Plug opening on compressor. Clean mating surfaces of residue. Replace "O" ring and apply a thin coat of refrigerant oil to surface. Remove plug and install relief valve. Evacuate and charge A/C system.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove coolant reservoir without disconnecting hose between reservoir and radiator. Remove bolts retaining upper radiator brackets to core support.
2. Remove discharge and condenser lines from condenser. Plug and cap openings. Remove bolts from upper condenser mounting brackets. Carefully move radiator back to clear condenser. Remove condenser, using caution not to bend fins on radiator or condenser. To install, reverse removal procedure. Replace "O" rings and lubricate with clean refrigerant oil. Evacuate and charge A/C system.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect refrigerant lines from evaporator, at firewall, in engine compartment. Cap and plug openings.
2. Remove instrument panel center lower cover. Remove right fuse box cover from instrument panel by pulling outward. Remove passenger instrument panel lower cover screws and pull downward to disengage clips and remove lower cover.
3. Remove screws from bottom of glove box assembly. Remove screw covers from upper corners of glove box assembly. Remove screws from behind covers and from latch hook in center of glove box. Disconnect electrical connector from rear of glove box. Remove glove box assembly.
4. Remove screws and bolts attaching glove box frame and passenger knee bolster to instrument panel. Disconnect electrical connector from evaporator temperature sensor. Remove bolts and nuts attaching evaporator unit to heater unit and blower unit. Remove evaporator.
5. Remove filter access cover and remove filters. Remove evaporator temperature sensor from evaporator fins. Remove screws holding housing halves together and carefully separate housing. Remove evaporator from housing. (Scheme 22)
6. If necessary, remove expansion valve. To install, reverse removal procedure. Replace "O" rings and lubricate with clean refrigerant oil. Evacuate and recharge A/C system.

Scheme 22

Remove evaporator unit. See EVAPORATOR UNIT. Remove evaporator temperature sensor from evaporator. To install, reverse removal procedure. Install evaporator temperature sensor as specified. (Scheme 22)

1. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article. Disconnect negative battery cable. Disconnect heater valve cable from heater valve arm. Turn heater valve arm to fully opened position (toward firewall).
2. Drain engine coolant. Remove heater valve mounting nut. Disconnect heater hoses from heater unit. Remove heater unit mounting nuts from firewall. Remove instrument panel. See «INSTRUMENT PANEL»(ref-35216-S42041028112001010900000).
3. Remove evaporator. See «EVAPORATOR UNIT»(ref-35216-S18071073072001010900000). Remove wiring harness clip and disconnect connectors from air mix control motor and mode control motor. Remove heater unit mounting bolt and remove heater unit. see scheme 3
4. To remove heater core, remove screws and pipe clamp. DO NOT bend heater core pipes. Remove heater core clamp. Remove heater core. To install, reverse removal procedure. Apply sealant to grommets. Refill cooling system.

Scheme 23

1. Disconnect negative battery cable. Remove instrument panel center lower cover. Remove right fuse box cover from instrument panel by pulling outward. Remove passenger instrument panel lower cover screws and pull downward to disengage clips and remove lower cover.
2. Remove screws from bottom of glove box assembly. Remove screw covers from upper corners of glove box assembly. Remove screws from behind covers and from latch hook in center of glove box. Disconnect electrical connector from rear of glove box. Remove glove box assembly. Remove screws and bolts attaching glove box frame and passenger knee bolster to instrument panel.
3. Remove shift knob. Remove beverage holder. Carefully pry on rear of center console panel and remove. Remove cover inside of center console compartment and remove all screws/nuts holding center console to floor. Disconnect all electrical connectors for center console and remove from vehicle.
4. Pull upward to disengage clips for passenger and driver side sill plates and remove. Grasp kick panels and pull toward center of vehicle to disengage clips and remove. Pry driver and passenger side "A" pillar covers inward to disengage clips and remove.
5. Disconnect combination switch connectors, ignition switch connectors and driver's side air bag connector. Disconnect any remaining electrical connectors to steering column. Remove steering joint cover from base of steering column. Remove upper and lower column covers.
6. Remove nuts and bolts attaching steering column to instrument panel. Lower steering column to allow removal of instrument panel. Disconnect steering shaft coupling and remove steering column (if necessary). (Scheme 23)
7. From driver's side, disconnect cabin and door wire harnesses from instrument panel driver's side fuse box. Disconnect instrument panel wire harness connector next to fuse box. From under driver's side of instrument panel, disconnect steering hanger beam harness and brake switch connector. On manual transmission models, disconnect clutch switch connectors.
8. On passenger's side, pull carpet back and disconnect connectors for SRS, ECM/PCM, air mix control motor, evaporator temperature sensor and antenna lead. Using a Torx bit, remove ground strap connected to floor.
9. From center console area, disconnect parking brake switch and harness clips. On automatic transmission models, disconnect parking pin switch and shift lock solenoid connectors.
10. From passenger side of instrument panel, disconnect connectors from passenger side fuse box. Disconnect instrument panel wire harness connector next to fuse box. From under passenger side of instrument panel, disconnect instrument panel, blower motor and associated connectors. Detach harness clip and connector clips.
11. Remove caps on driver side of dash and remove bolts from inside cap openings. Remove bolts from behind glove box opening and from center console area. Pull instrument panel rearward to disengage guide pins. (Scheme 24)
12. Once all connectors are disconnected and instrument panel is clear, carefully remove instrument panel from vehicle through door opening. To install, reverse removal procedure. When installing instrument panel, make sure guide pins fit properly.

Scheme 24

Carefully pry sensor from instrument panel using caution not to scratch sensor or instrument panel. Disconnect electrical connector and aspirator hose. To install, reverse removal procedure. Make sure aspirator hose is properly connected to sensor when installing.

Disconnect air mix control motor connector. Remove linkage rod from motor. Remove self-tapping screws holding motor to heater unit. see scheme 3and (Scheme 25). Remove actuator. To install, reverse removal procedure. Verify air mix motor operation.

Scheme 25

Disconnect mode control motor connector and wiring harness clip. Disconnect mode control linkage. Remove screws attaching mode control motor to A/C-heater module. see scheme 3and (Scheme 26). To install, reverse removal procedure.

Scheme 26

Disconnect recirculation control motor connector. Remove screws attaching recirculation control motor to A/C-heater module. see scheme 3and (Scheme 27). To install, reverse removal procedure.

Scheme 27

Sensor is located behind lower radiator air inlet grille on front bumper. Disconnect connector from outside air temperature sensor. Release locking tab and remove sensor from bracket. To install, reverse removal procedure.

Disconnect negative battery cable. Pull carpet back on driver and passenger side of center console. Remove bolts securing PCM to floor. Disconnect electrical connectors. Remove PCM from vehicle. To install, reverse removal procedure.

Use small flat bladed screwdriver and carefully remove sunlight sensor from top center of instrument panel. Unplug connector. To install sensor, reverse removal procedure.