Climate Control System: Removal & Installation Honda Crosstour I

Receiver/Dryer Desiccant Replacement

Note. Install the receiver/dryer as quickly as possible to prevent the system from absorbing moisture from the air.

Scheme 79

1. Remove the A/C condenser (see «A/C CONDENSER REPLACEMENT»(ref-360068-S08882814602010042600000) ).
2. Remove the bolts from the A/C condenser, then remove the receiver/dryer (A), the bracket (B), and the O-rings (C).
3. Install the receiver/dryer in the reverse order of removal. Replace the O-rings with new ones, and apply a thin coat of refrigerant oil (DENSO ND-OIL 8) before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage.

A/C Compressor Replacement

Note. Do not install the A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure.

Scheme 80

Scheme 81

1. If the A/C 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. Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-360068-S36795137242010042600000) ).
3. Remove the A/C condenser fan shroud (see «FAN, FAN MOTOR, AND SHROUD REMOVAL AND INSTALLATION»(ref-360063-S22278466622010042600000) ), and the alternator (see «DRIVE BELT AUTO-TENSIONER AIR BLEEDING»(ref-360069-S30326291402010042600000) ).
4. Remove the bolts and the nut, then disconnect the suction hose (A) and the discharge hose (B) from the A/C compressor. Remove the O-rings (C). Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
5. Remove the mounting bolts and the A/C compressor (A). Be careful not to damage the radiator fins when removing the A/C compressor.
6. Install the A/C compressor in the reverse order of removal, and note these items: Inspect the A/C lines for any signs of contamination. If you're installing a new A/C compressor, you must calculate the amount of refrigerant oil to be removed from it (see «A/C REFRIGERANT OIL REPLACEMENT»(ref-360068-S28664823702010042600000) ). A new A/C compressor comes with a full charge of oil. 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 correct O-rings for HFC-134a (R-134a) to avoid leakage. Use only PAG refrigerant oil (DENSO ND-OIL 8) for HFC-134a DENSO A/C systems. 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, reinstall 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 A/C compressor and the A/C condenser fan shroud. Charge the system (see «SYSTEM CHARGING»(ref-360068-S02009729602010042600000) ).

A/C Compressor Relief Valve Replacement

Note. If the A/C compressor relief valve released refrigerant to the atmosphere, determine and correct the cause of the excessive system pressure, then replace the relief valve.

Scheme 82

1. Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-360068-S36795137242010042600000) ).
2. Raise the vehicle on a lift.
3. Remove the relief valve (A) and the O-ring (B). Plug the opening to keep foreign matter from entering the system, and the A/C compressor oil from running out.
4. Clean the mating surfaces.
5. Replace the O-ring on the relief valve, and apply a thin coat of refrigerant oil before installing it.
6. Remove the plug you installed in step 2 , then install and tighten the relief valve.
7. Charge the system (see «SYSTEM CHARGING»(ref-360068-S02009729602010042600000) ).

A/C Refrigerant Oil Replacement

Recommended PAG oil: DENSO ND-OIL 8

P/N 38897-PR7-A01AH: 120 mL (4 fl-oz)

It is important to have the correct amount of refrigerant oil in the A/C system to ensure proper lubrication of the A/C compressor.

Too little oil damages the A/C compressor; too much oil reduces the cooling capacity of the system, and can produce high vent temperatures.

1. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
2. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption.
3. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately.

Add the recommended refrigerant oil in the amount listed if you replace any of the following parts.

A/C condenser (including Dryer Desiccant)..................50 mL (1 2/3 fl-oz)

Evaporator................40 mL (1 1/3 fl-oz)

Line or hose..............10 mL (1/3 fl-oz)

Leakage repair..........25 mL (5/6 fl-oz)

A/C compressor........For A/C compressor replacement, subtract the volume of oil drained from the removed A/C compressor from 82 mL (2 7/9 fl-oz), and drain the calculated volume of oil from the new A/C compressor: 82 mL (2 7/9 fl-oz) - Volume of removed A/C compressor = Volume to drain from new A/C compressor.

Note. Even if no oil is drained from the removed A/C compressor, do not drain more than 50 mL (1 2/3 fl-oz) from the new A/C compressor.

Scheme 83

Scheme 84

Scheme 85

Scheme 86

1. Open the glove box. Remove the glove box stop on the right side, then let the glove box hang down (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-360087-S33745899912010042600000) ).
2. Remove the dust and pollen filter assembly (A) from the blower unit.
3. Remove the filter (A) from the housing (B), and replace the filter.
4. Install the filter in the reverse order of removal. Make sure that there is no air leaking out of the blower unit.

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

1. Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-360087-S33745899912010042600000) ).
2. Remove the passenger's undercover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-360087-S14123292982010042600000) ).
3. Remove the right kick panel (see «TRIM REMOVAL/INSTALLATION - DOOR AREAS»(ref-360104-S22618986532010042600000) ).
4. Remove the dust and pollen filter assembly from the blower unit.
5. Remove the bolts (A) and the wire harness clip (B). Then cut the plastic cross brace (C) in the glove box opening with diagonal cutters in the area shown. Retain the plastic cross brace to be reinstalled later.
6. Disconnect these connectors (A): Passenger's under-dash fuse/relay box connector D (28P), the stereo amplifier connectors A (24P) and B (18P), the AM/FM antenna lead (3P), and right side wire harness connector C508 (20P). Remove the wire harness clips (B).
7. Disconnect the connector (A) from the blower motor, and detach the wire harness clip (B). Remove the self-tapping screw and the mounting nut.
8. Remove the self-tapping screws, and the passenger's heater duct (A).
9. Disconnect the connector (A) from the recirculation control motor. Remove the mounting nuts.
10. Pull the blower unit (A) out while rotating it clockwise as shown, so that the glove box bracket (B) passes through the dust and pollen filter area.
11. Install the unit in the reverse order of removal. Make sure that there is no air leakage.

Blower Unit Component Replacement

Note these items when overhauling the blower unit

Scheme 93

1. The recirculation control motor (A), the blower motor (B), and the dust and pollen filter (C) can be replaced without removing the blower unit.
2. Before reassembly, make sure that the recirculation control linkage and door move smoothly without binding.
3. After reassembly, make sure the recirculation control motor runs smoothly (see «RECIRCULATION CONTROL MOTOR TEST»(ref-360068-S21783354912010042600000) ).

Scheme 94

1. Remove the evaporator core (see «EVAPORATOR CORE REPLACEMENT»(ref-360068-S28707449412010042600000) ).
2. Remove the insulator (A) and bolts, then remove the expansion valve (B) and O-rings (C).
3. Install the expansion valve in the reverse order of removal, and note these items: 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 correct O-rings for HFC-134a (R-134a) to avoid leakage. Immediately after using the oil, reinstall 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. Make sure that there is no air leakage. Charge the system (see «SYSTEM CHARGING»(ref-360068-S02009729602010042600000) ).

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

1. Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-360068-S36795137242010042600000) ).
2. Remove the bolt from the A/C line clamp (A), and remove the receiver line from the clamp (B).
3. Remove the bolt, then disconnect the A/C line (A) from the evaporator core, and the O-rings (B).
4. Remove the blower unit (see «BLOWER UNIT REMOVAL/INSTALLATION»(ref-360068-S24361702532010042600000) ).
5. Remove the passenger's air mix motor (see «PASSENGER'S AIR MIX CONTROL MOTOR REPLACEMENT»(ref-360068-S37194873912010042600000) ).
6. Remove the passenger's console cover (see «WITH NAVIGATION SYSTEM»(ref-360087-S34319023992010042600000) ).
7. Disconnect these connectors (A): The evaporator temperature sensor, and the power transistor. Remove the connector clip (B) and the harness clip (C). Remove the self-tapping screws, the expansion valve cover (D), and the seal (E).
8. Carefully pull out the evaporator core (A) without bending, the lines.
9. Remove the clip (A) and the evaporator temperature sensor (B). NOTE: At the factory, the evaporator temperature sensor is installed at the 13th row of fins from the right side.
10. When the evaporator temperature sensor (A) is reinstalled onto a new evaporator core, set the evaporator temperature sensor in the 13th fin from the right side. NOTE: If you are installing the sensor onto the old evaporator core, install the sensor onto the 14th fin, because the 13th fin may be deformed from the previous installation.
11. Install the core in the reverse order of removal, and note these items: If you're installing a new evaporator core, add refrigerant oil (DENSO ND-OIL 8) (see «A/C REFRIGERANT OIL REPLACEMENT»(ref-360068-S28664823702010042600000) ). 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 correct O-rings for HFC-134a (R-134a) to avoid leakage. Immediately after using the oil, reinstall 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. Make sure that there is no air leakage. Charge the system (see «SYSTEM CHARGING»(ref-360068-S02009729602010042600000) ).

Heater Unit/Core Replacement

SRS components are located in this area. Review the SRS component locations (see COMPONENT LOCATION INDEX ) and the precautions and procedures (see PRECAUTIONS AND PROCEDURES ) before doing repairs or service.

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

1. Do the battery terminal disconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-360074-S34095844792010042600000) ).
2. Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-360068-S36795137242010042600000) ).
3. Disconnect the A/C line from the evaporator core (see «EVAPORATOR CORE REPLACEMENT»(ref-360068-S28707449412010042600000) ).
4. When the engine is cool, drain the engine coolant from the radiator (see «COOLANT CHECK»(ref-360063-S27042747542010042600000) ).
5. From under the hood, slide the hose clamps (A) back. Disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater unit. Note the layout of the hoses. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately.
6. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines or brake lines, etc.
7. Remove the dashboard (see «DASHBOARD/STEERING HANGER BEAM REMOVAL/INSTALLATION»(ref-360087-S09280119122010042600000) ).
8. Disconnect the connector (A). Remove the clips (B), ducts (C), and the drain hose (D). Then remove the mounting nuts, and the blower-heater unit (E).
9. Disconnect the connector (A) from the blower motor, and detach the wire harness clip (B).
10. Disconnect these connectors (A): The mode control motor, the power transistor, the evaporator temperature sensor, the passenger's air mix control motor, and the recirculation control motor. Remove the wire harness clips (B).
11. Disconnect the connector (A) from the driver's air mix control motor. Remove the wire harness clips (B), the connector clip (C), and the wire harness (D).
12. Remove the passenger's air mix control motor (see «PASSENGER'S AIR MIX CONTROL MOTOR REPLACEMENT»(ref-360068-S37194873912010042600000) ).
13. Remove the self-tapping screws and the passenger's heater duct (A). Remove the self-tapping screws and the expansion valve cover (B). Remove the self-tapping screw and the heater core cover (C). Remove the self-tapping screws, the heater pipe bracket (D), and the grommet (E), and carefully pull out the heater core (F).
14. Install the heater core and the evaporator core in the reverse order of removal.
15. Install the heater unit in the reverse order of removal, and note these items: Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. Refill the cooling system with engine coolant (see «COOLANT CHECK»(ref-360063-S27042747542010042600000) ). Make sure that there is no coolant leakage. Make sure that there is no air leakage.
16. Do the battery terminal reconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-360074-S34095844792010042600000) ).

Scheme 108

1. Remove the driver's dashboard undercover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-360087-S14123292982010042600000) ).
2. Disconnect the 7P connector (A) from the air mix control motor (B). Remove the self-tapping screws and the air mix control motor from the heater unit.
3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.

Scheme 109

1. Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-360087-S33745899912010042600000) ).
2. Disconnect the 7P connector (A) from the passenger's air mix control motor (B). Remove the self-tapping screws and the passenger's air mix control motor from the heater unit.
3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.

Scheme 110

1. Remove the blower unit (see «BLOWER UNIT REMOVAL/INSTALLATION»(ref-360068-S24361702532010042600000) ).
2. Disconnect the 7P connector (A) from the mode control motor (B). Remove the self-tapping screws and the mode control motor from the heater unit.
3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.

Scheme 111

1. Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-360087-S33745899912010042600000) ).
2. Disconnect the 7P connector (A) from the recirculation control motor (B). Remove the self-tapping screws and the recirculation control motor from the heater unit.
3. Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.

Scheme 112

1. Remove the driver's inner dashboard trim (see «DRIVER'S OUTER DASHBOARD TRIM REMOVAL/INSTALLATION»(ref-360087-S27244399042010042600000) ).
2. Disconnect the connector (A), and remove the humidity/in-car temperature sensor (B) from the air hose (C).
3. Install the sensor in the reverse order of removal. Be sure to connect the air hose securely.

Scheme 113

1. Lift the tab (A) to release the lock, then remove the outside air temperature sensor (B) from the front bumper beam. Disconnect the 2P connector (C) from the outside air temperature sensor.
2. Install the sensor in the reverse order of removal.

Scheme 114

1. Pull out the sunlight sensor (A) from the dashboard, and disconnect the connector (B), and remove the sunlight sensor. Be careful not to damage the sensor and the dashboard.
2. Install the sensor in the reverse order of removal.

Scheme 115

1. Remove the passenger's dashboard undercover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-360087-S14123292982010042600000) ).
2. Disconnect the connectors (A). Loosen the bolt (B) and remove the bolts (C) from the climate control unit (D).
3. Install the unit in the reverse order of removal. After installation, operate the various functions to make sure they work properly.
4. Run the self-diagnostic function to confirm that there are no problems in the system (see «HOW TO USE THE SELF-DIAGNOSTIC FUNCTION WITHOUT THE HDS»(ref-360068-S32342889962010042600000) ).

Scheme 116

1. Remove the audio unit (see «WITHOUT NAVIGATION SYSTEM»(ref-360124-S26142092282010042600000) ).
2. Remove the self-tapping screws and the climate control unit (A). If necessary, replace the bulbs (B).
3. Install the unit in the reverse order of removal.
4. Run the self-diagnostic function to confirm that there are no problems in the system (see «HOW TO USE THE SELF-DIAGNOSTIC FUNCTION WITHOUT THE HDS»(ref-360068-S32342889962010042600000) ).

Scheme 117

1. Remove the audio unit (see «AUDIO UNIT REMOVAL/INSTALLATION»(ref-360124-S11397871042010042600000) ).
2. Remove the self-tapping screws and the driver's climate control switch (A), and the passenger's climate control switch (B).
3. Install the switches in the reverse order of removal.
4. Run the self-diagnostic function to confirm that there are no problems in the system (see «HOW TO USE THE SELF-DIAGNOSTIC FUNCTION WITHOUT THE HDS»(ref-360068-S32342889962010042600000) ).

Scheme 118

Scheme 119

1. Remove the climate control switch (see «CLIMATE CONTROL SWITCH REMOVAL/INSTALLATION»(ref-360068-S16197407862010042600000) ).
2. Remove the screws and cover (A) from the driver's climate control switch (B).
3. Remove the bulb(s) (A) with a flat-tip screwdriver.
4. Install the bulb(s) in the reverse order of removal. After installation, operate the various functions to see whether it works properly.