Heating/air Conditioning: Removal & Installation Honda Element I

A/C Refrigerant Oil Replacement

Recommended PAG oil: DENSO ND-OIL 8

1. P/N 38897-PR7-A01AH: 120 mL (4 fl.oz)
2. P/N38899-PR7-A01: 40 mL (1 1/3 fl.oz)

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

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, replace 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.

A/C condenser....25 mL (5/6 fl.oz)

Evaporator.......45 mL (1 1/2 fl.oz)

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

Receiver/Dryer......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 160 mL (5 1/3 fl.oz), and drain the calculated volume of oil from the new A/C compressor: 160 mL (5 1/3 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, don't drain more than 50 mL (1 2/3 fl.oz) from the new A/C compressor.

Scheme 62

Scheme 63

Blower Unit Component Replacement

Note these items when overhauling the blower unit

1. The recirculation control motor (A), the power transistor (B), the blower motor (C), and the dust and pollen filters (with A/C) (D) can be replaced without removing the blower unit.
2. Before reassembly, make sure that the recirculation control linkage and doors move smoothly.
3. After reassembly, make sure the recirculation control motor runs smoothly (see «MODE CONTROL MOTOR REPLACEMENT»(ref-220611-S12900188292006022100000) ).

Scheme 64

Heater Unit/Core Replacement

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

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.
2. Disconnect the negative cable from the battery.
3. With air conditioning; disconnect the A/C lines from the evaporator core (see «EVAPORATOR CORE REPLACEMENT»(ref-220611-S16203314032006022100000) ).
4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown.
5. When the engine is cool, drain the engine coolant from the radiator (see «COOLANT CHECK»(ref-220567-S24374111712006022000000) ).
6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let engine coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately.
7. Remove the mounting bolt and the heater valve as shown. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines and the brake lines, etc.
8. Remove the dashboard (see «DASHBOARD REMOVAL/INSTALLATION»(ref-220597-S22432212742006022100000) ).
9. Remove the ECM/PCM (see «ECM/PCM REPLACEMENT»(ref-220570-S29077717572006022000000) ).
10. Disconnect the connectors (A) from the dashboard wire harness, the air mix control motor, the evaporator temperature sensor, the power transistor, the mode control motor, the blower motor, and the recirculation control motor, then remove the wire harness clips (B), the connector clips (C), the wire harness (D), the heater duct (E), and the clip (F). Disconnect the drain hose (G), then remove the mounting nuts and the blower-heater unit (H).
11. Remove the self-tapping screws and the expansion valve cover (A). With air conditioning; carefully pull out the evaporator core (with A/C) (B) so you don't bend the inlet and outlet pipes. Remove the self-tapping screws and the flange cover (C), then remove the grommet (D), and carefully pull out the heater core (E) so you don't bend the inlet and outlet pipes.
12. Install the heater core and the evaporator core (with A/C) in the reverse order of removal.
13. 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-220567-S24374111712006022000000) ). Be sure to connect the drain hose securely. Adjust the heater valve cable (see «HEATER VALVE CABLE ADJUSTMENT»(ref-220611-S31336786322006022100000) ). Make sure that there is no engine coolant leakage. Make sure that there is no air leakage. With air conditioning, refer to evaporator core replacement (see «EVAPORATOR CORE REPLACEMENT»(ref-220611-S16203314032006022100000) ). Enter the anti-theft codes for the radio, then enter the audio presets.

Scheme 70

Scheme 71

Scheme 72

1. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C).
2. From under the dash, disconnect the heater valve cable housing from the cable clamp (A), and disconnect the heater valve cable (B) from the air mix control linkage (C).
3. Set the temperature control dial on Max Cool with the ignition switch ON (II).
4. Attach the heater valve cable (B) to the air mix control linkage (C) as shown in step 2 . Hold the end of the heater valve cable housing against the stop (D), then snap the heater valve cable housing into the cable clamp (A).
5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A).

Scheme 73

1. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Turn the evaporator temperature sensor clockwise to the stop, and carefully pull it out.
2. Install the sensor in the reverse order of removal.

Scheme 74

Scheme 75

1. Dip the sensor in ice water, and measure the resistance between its terminals.
2. Then pour warm water on the sensor, and check for a change in resistance.
3. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the specifications.

Scheme 76

Scheme 77

Scheme 78

1. Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-220611-S19543847392006022100000) ).
2. Remove the bolt, then disconnect the suction line (A) and the receiver line (B) from the evaporator core.
3. Remove the blower unit (see «BLOWER UNIT REMOVAL AND INSTALLATION»(ref-220611-S11640615812006022100000) ).
4. Remove the bolt and the ECM/PCM bracket (A). Remove the self-tapping screws and the expansion valve cover (B).
5. Carefully pull out the evaporator core without bending the pipes.
6. 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 page «A/C SERVICE TIPS AND PRECAUTIONS»(ref-220611-S14866115562006022100000) . 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-220611-S02990373832006022100000) ).

Scheme 79

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. 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 (see «REFRIGERANT RECOVERY»(ref-220611-S19543847392006022100000) ).
5. Remove the radiator reservoir tank.
6. Remove the power steering pump (see «PUMP REPLACEMENT»(ref-220584-S03510884652006022000000) ).
7. Remove the alternator (see «ALTERNATOR REMOVAL AND INSTALLATION»(ref-220559-S01764025892006022000000) ).
8. Remove the bulkhead cover and bulkhead (see «RADIATOR AND FAN REPLACEMENT»(ref-220567-S12659532182006022000000) ).
9. Remove the A/C compressor clutch connector (A) from the A/C condenser fan shroud (B), then open the wire harness clip. Disconnect the A/C condenser fan connector (D). Remove the upper mounting bolts and the A/C condenser fan shroud. Be careful not to damage the radiator fins when removing the A/C condenser fan shroud.
10. Disconnect the A/C compressor clutch connector (A), remove the nuts, then disconnect the suction line (B) and the discharge line (C) from the A/C compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
11. Remove the mounting bolts and the A/C compressor. Be careful not to damage the radiator fins when removing the A/C compressor.
12. Install the A/C compressor in the reverse order of removal, and note these items: If you're installing a new A/C compressor, you must calculate the amount of refrigerant oil to be removed from it (see page «A/C SERVICE TIPS AND PRECAUTIONS»(ref-220611-S14866115562006022100000) . 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 refrigerant oil (DENSO ND-OIL 8) for HFC-134a DENSO piston type A/C 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, 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-220611-S02990373832006022100000) ). Do the ECM/PCM idle learn procedure (see «ECM/PCM IDLE LEARN PROCEDURE»(ref-220572-S08440202922006022000000) ). Perform the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-220630-S35739607722006022100000) ). Enter the anti-theft code for the radio, then enter the audio presets. Reset the clock.

Scheme 82

Scheme 83

Scheme 84

1. Check the pressure plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set (see «A/C COMPRESSOR CLUTCH OVERHAUL»(ref-220611-S07172796122006022100000) ).
2. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag (see «A/C COMPRESSOR CLUTCH OVERHAUL»(ref-220611-S07172796122006022100000) ).
3. Measure the clearance between the pulley (A) and the pressure plate (B) with a dial indicator. Zero out the indicator, then apply battery voltage to the A/C compressor clutch. Measure the movement of the pressure plate when the voltage is applied. If the clearance is not within the specified limits, the pressure plate must be reshimmed (see «A/C COMPRESSOR CLUTCH OVERHAUL»(ref-220611-S07172796122006022100000) ). Clearance: 0.35-0.6 mm (0.014-0.024 in.) NOTE: The shims are available in three thicknesses: 0.1 mm, 0.3 mm, and 0.5 mm.
4. Check resistance of the field coil. If resistance is not within specifications, replace the field coil (see «A/C COMPRESSOR CLUTCH OVERHAUL»(ref-220611-S07172796122006022100000) ). Field Coil Resistance: 3.9-4.3 ohms at 68°F (20°C)