Heating/air Conditioning: Removal & Installation Honda Pilot I

A/C Refrigerant Oil Replacement

Recommended PAG oil: DENSO ND-OIL 8

1. P/N 38897-PR7-A01AH: 120ml (4 fl. oz.)
2. P/N 38899-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, 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.

Condenser: 35 ml (1 1/6 fl. oz.)

Front Evaporator:40 ml (1 1/3 fl. oz.)

Rear Evaporator: 30 ml (1 fl. oz.)

Line Or Hose: 10 ml (1/3 fl. oz.)

Leakage Repair: 25 ml (5/6 fl. oz.)

Compressor For compressor replacement, subtract the volume of oil drained from the removed compressor from 180 ml (6 fl. oz.), and drain the calculated volume of oil from the new compressor: 180 ml (6 fl. oz.) - Volume of removed compressor = Volume to drain from new compressor.

Note. Even if no oil is drained from the removed compressor, don't drain more than 50 ml (12/3 fl. oz.) from the new compressor.

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Dust & Pollen Filter Replacement

The dust and pollen filter should be replaced every 30,000 miles (48,000 km) or 24 months, whichever comes first. Replace the filter more often if the airflow is less than usual, or if the vehicle is driven in areas that have high concentrations of soot from industry or diesel powered vehicles.

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1. Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-174030-S37812666562005042500000) ).
2. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown, and discard it.
3. Remove the bolts, the screws and the glove box frame.
4. Remove the filter lid (A) from the evaporator, then pull out the dust and pollen filter (B). Note the direction of the arrow.
5. Install the filter in the reverse order of removal. Note the direction of the arrow. Make sure that there is not air leaking out of the evaporator. Note the direction of the arrow.
6. Install the glove box frame and glove box in the reverse order of removal.

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1. Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-174036-S22803969732005041500000) ).
2. Disconnect the suction line (A) and receiver line (B) from the evaporator. Remove the mounting nut. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
3. Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-174030-S37812666562005042500000) ).
4. Remove the plastic cross brace, then remove the glove box frame (see «DUST & POLLEN FILTER REPLACEMENT»(ref-174036-S20085851502005041500000) ).
5. Remove the wire harness connector (A). Disconnect the evaporator temperature sensor connector (B). Remove the self-tapping screws, the mounting nuts, the mounting bolts, the bracket (C), and the evaporator (D).
6. Install the evaporator in the reverse order of removal, and note these items. If you're installing a new evaporator, add refrigerant oil (DENSO ND-OIL 8) (see «A/C REFRIGERANT OIL REPLACEMENT»(ref-174036-S21140871522005041500000) ). 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-174036-S42278027222005041500000) ).

Scheme 92

1. Remove the filter lid (A), then pull out the dust and pollen filter (B).
2. Pull out the evaporator temperature sensor (C) from the evaporator fins.
3. Remove the screws, carefully separate the upper housing (D) from the lower housing (E), then remove the evaporator core (F).
4. If necessary, remove the expansion valve (G).
5. Reassemble the evaporator in the reverse order of disassembly, and note these items: Replace all 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. Reinstall the evaporator temperature sensor bulb (H) and clip in their original location. Make sure no air is leaking from the upper housing and the lower housing fitting.

Blower Unit Removal & Installation

SRS components are located in this area. Review the SRS components locations, precautions and procedures before performing repairs or service. For 2003 models, see AIR BAG RESTRAINT SYSTEMS . For 2004 models, see AIR BAG RESTRAINT SYSTEMS .

Scheme 93

1. Make sure you have the anti-theft code for the radio and the navigation system, then write down the frequencies for the radio's preset buttons.
2. Disconnect the negative cable from the battery.
3. Remove the dashboard (see «DASHBOARD REMOVAL/INSTALLATION»(ref-174030-S21230409012005042500000) ).
4. Remove the evaporator (see «EVAPORATOR REMOVAL & INSTALLATION»(ref-174036-S34505667092005041500000) ).
5. Remove the wire harness clip (A). Remove the mounting nuts, the mounting bolt, and the blower unit (B).
6. Install the unit in the reverse order of removal, and note these items: For evaporator and A/C-related information, refer to evaporator removal and installation (see «EVAPORATOR REMOVAL & INSTALLATION»(ref-174036-S34505667092005041500000) ). Do the PCM idle learn procedure (see «PCM IDLE LEARN PROCEDURE»(ref-173998-S03649363492005041500000) ). Do the power window control unit resetting procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-174055-S11132043692005042800000) ). Enter the anti-theft code for the radio and the navigation system, then enter the customer's radio station presets.

Blower Unit Component Replacement

Note these items when overhauling the blower unit

Scheme 94

1. The recirculation control motor (A), the power transistor (B) and the blower motor (C) can be replaced without removing the blower unit.
2. Before reassembly, make sure that the recirculation control linkage and doors move smoothly without binding.
3. After reassembly, make sure the recirculation control motor runs smoothly (see «RECIRCULATION CONTROL MOTOR TEST»(ref-174036-S36089174992005041500000) ).

Heater Unit/Core Replacement

SRS components are located in this area. Review the SRS components locations, precautions and procedures before performing repairs or service. For 2003 models, see AIR BAG RESTRAINT SYSTEMS . For 2004 models, see AIR BAG RESTRAINT SYSTEMS .

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1. Make sure you have the anti-theft code for the radio and the navigation system, then write down the frequencies for the radio's preset buttons.
2. Disconnect the negative cable from the battery.
3. 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.
4. When the engine is cool, drain the engine coolant from the radiator (see «COOLANT REPLACEMENT»(ref-173994-S39601808142005041500000) ).
5. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater unit. 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, the brake lines, etc.
7. Remove the dashboard (see «DASHBOARD REMOVAL/INSTALLATION»(ref-174030-S21230409012005042500000) ).
8. Remove the evaporator (see «EVAPORATOR REMOVAL & INSTALLATION»(ref-174036-S34505667092005041500000) ).
9. Remove the mounting bolts and the heater unit.
10. Remove the self-tapping screws and the clamp (A), then carefully pull out the heater core (B) so you don't bend the inlet and outlet pipes.
11. Install the heater core in the reverse order of removal.
12. 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 REPLACEMENT»(ref-173994-S39601808142005041500000) ). Adjust the heater valve cable (see «HEATER VALVE CABLE ADJUSTMENT»(ref-174036-S42553058012005041500000) ). Make sure that there is no coolant leakage. Make sure that there is no air leakage. For evaporator and A/C-related information, refer to evaporator removal and installation (see «EVAPORATOR REMOVAL & INSTALLATION»(ref-174036-S34505667092005041500000) ). Do the PCM idle learn procedure (see «PCM IDLE LEARN PROCEDURE»(ref-173998-S03649363492005041500000) ). Do the power window control unit resetting procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-174055-S11132043692005042800000) ). Enter the anti-theft code for the radio and the navigation system, then enter the customer's radio station presets.

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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 to Max Cool with the ignition switch ON (II).
4. Attach the heater valve cable (B) to the air mix control linkage (C) as shown 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).

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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 and the navigation system, 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-174036-S22803969732005041500000) ).
5. Remove the alternator (see «ALTERNATOR»(ref-162803-S23346743602004061000000) ).
6. Remove the compressor clutch connector (A) from the condenser fan shroud (B), then disconnect the connector. 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, then remove the bolts from the cooler line brackets (F). Loosen the lower mounting bolts, 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 line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
8. Remove the mounting bolts and the compressor. Be careful not to damage the radiator fins when removing the compressor.
9. If necessary, remove the mounting bolts and the compressor bracket.
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 «A/C REFRIGERANT OIL REPLACEMENT»(ref-174036-S21140871522005041500000) ). 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 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 compressor or the condenser fan shroud. Charge the system (see «SYSTEM CHARGING»(ref-174036-S42278027222005041500000) ). Do the PCM idle learn procedure (see «PCM IDLE LEARN PROCEDURE»(ref-173998-S03649363492005041500000) ). Do the power window control unit resetting procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-174055-S11132043692005042800000) ). Enter the anti-theft code for the radio and the navigation system, then enter the customer's radio station presets.

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1. Check the pressure plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set (see «COMPRESSOR CLUTCH OVERHAUL»(ref-174036-S20700844842005041500000) ).
2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag (see «COMPRESSOR CLUTCH OVERHAUL»(ref-174036-S20700844842005041500000) ).
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 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 reshimed (see «COMPRESSOR CLUTCH OVERHAUL»(ref-174036-S20700844842005041500000) ). Clearance - 0.5 +/- 0.15mm (0.020 +/- 0.006") 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 «COMPRESSOR CLUTCH OVERHAUL»(ref-174036-S20700844842005041500000) ). Field Coil Resistance - 3.4-3.8 ohms at 68°F (20°C)