Heating/air Conditioning: Removal & Installation Honda Pilot II

A/C Refrigerant Oil Replacement

Recommended PAG oil: DENSO ND-OIL8

1. P/N 38897-PR7-A01AH: 120 mL (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.

A/C condenser

(including Dryer

Desiccant).................50 mL (1 2/3 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)

Receiver/Dryer

Desiccant..................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 125 mL (4 2/9 fl.oz), and drain the calculated volume of oil from the new A/C compressor. 125 mL (4 2/9 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, don't drain more than 50 mL (1 2/3 fl.oz) from the new A/C compressor.

Scheme 63

Scheme 64

Blower Unit Component Replacement

Note these items when overhauling the blower unit

Scheme 65

1. The recirculation control motor (A), front 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-333580-S37037944402009072100000) ).

Scheme 66

1. Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-333580-S26852216912009072100000) ).
2. Remove the front evaporator core (see «FRONT EVAPORATOR CORE REPLACEMENT»(ref-333580-S22387255722009072100000) ).
3. Remove the bolts, then remove the front expansion valve (A) and O-rings (B).
4. Install the front 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-333580-S36054889922009072100000) ).

Scheme 67

Scheme 68

Scheme 69

Scheme 70

1. Recover the refrigerant with a recovery/recycling/charging station, (see «REFRIGERANT RECOVERY»(ref-333580-S26852216912009072100000) )
2. Remove the bolts.
3. Remove the bolts, then disconnect the front receiver line (A) and the front suction line (B) from the front evaporator core. Remove the O-rings (C).
4. Remove the blower unit (see «BLOWER UNIT REMOVAL/INSTALLATION»(ref-333580-S00246683242009072100000) ).
5. Disconnect the connector (A) from the front power transistor, then remove the harness clip (B). Remove the self-tapping screws, the expansion valve cover (C), and the seal (D).
6. Remove the bolts, the inlet and outlet pipes (A), and expansion valve (B). Carefully pull out the front evaporator core (C), then remove the plate (D).
7. Install the core in the reverse order of removal, and note these items: If you're installing a new front evaporator core, add refrigerant oil (DENSO ND-OIL 8) (see «A/C SERVICE TIPS AND PRECAUTIONS»(ref-333580-S21936242842009072100000) ). 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-333580-S36054889922009072100000) ).

Heater Unit/Core Replacement

SRS components are located in this area. Review the SRS COMPONENT LOCATION INDEX and PRECAUTIONS AND PROCEDURES before doing repairs or service.

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

1. Do the battery terminal disconnection procedure, (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-333608-S13381695222009072100000) )
2. Disconnect the front receiver line and front suction line from the front evaporator core (see «FRONT EVAPORATOR CORE REPLACEMENT»(ref-333580-S22387255722009072100000) ).
3. When the engine is cool, drain the engine coolant from the radiator (see «COOLANT REPLACEMENT»(ref-333555-S19429433502009072100000) ).
4. 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 orientation of the hose. 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.
5. Remove the mounting nuts from the heater unit. Take care not to damage or bend the fuel lines or the brake lines, etc.
6. Remove the dashboard (see «DASHBOARD REPLACEMENT»(ref-333587-S26684108782009072100000) ).
7. Disconnect the connector (A) from the front blower motor. Remove the wire harness clips (B).
8. Disconnect the connectors (A) from the front mode control motor, the passenger's air mix control motor (with climate control), the recirculation control motor, and the front power transistor. Remove the wire harness clips (B).
9. Disconnect the connectors (A) from the air mix control motor and the front evaporator temperature sensor. Remove the wire harness clips (B) and the wire harness (C).
10. Turn over the carpet. Remove the clip (A) and remove the rear heater duct (B).
11. Remove the mounting nuts and bolts. Slide the blower-heater unit (A) back, then remove the drain hose (B) and blower-heater unit.
12. 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 front heater core cover (C). Remove the self-tapping screws, the heater pipe brackets (D), the grommets (E), and carefully pull out the front heater core (F).
13. Install the front heater core, and the front evaporator core in the reverse order of removal.
14. Install the heater unit in the reverse order of removal, and note these items: Do not interchange the inlet and the outlet heater hoses. Install the inlet and the outlet hose clamps securely. Refill the cooling system with engine coolant (see «COOLANT REPLACEMENT»(ref-333555-S19429433502009072100000) ). Make sure that there is no coolant leakage. Make sure that there is no air leakage. Refer to «FRONT EVAPORATOR CORE REPLACEMENT»(ref-333580-S22387255722009072100000) .
15. Do the battery terminal reconnection procedure, (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-333608-S13381695222009072100000) )

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 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. Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-333580-S26852216912009072100000) ).
3. Remove the drive belt (see «DRIVE BELT REPLACEMENT»(ref-333547-S39082279042009072100000) ).
4. Remove the front splash shield (see «SPLASH SHIELD REPLACEMENT»(ref-333594-S31882515052009072100000) ).
5. Support the front subframe with the engine support. Remove the bolts and the front sub-frame stiffener (A). Then remove the harness clip (B). NOTE: Install the new front subframe mounting bolt (C).
6. Disconnect the A/C compressor clutch connector (A). Remove the bolts and the nut, then disconnect the suction hose (B) and discharge hose (C) from the A/C compressor. Remove the O-rings (D). Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
7. Remove the mounting bolts and the A/C compressor (A). Be careful not to damage the radiator fins when removing the compressor.
8. 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 SERVICE TIPS AND PRECAUTIONS»(ref-333580-S21936242842009072100000) ). 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 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 compressor and the A/C condenser fan shroud. Charge the system (see «SYSTEM CHARGING»(ref-333580-S36054889922009072100000) ).

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-333580-S34490653552009072100000) ).
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 «A/C COMPRESSOR CLUTCH OVERHAUL»(ref-333580-S34490653552009072100000) ).
3. Measure the clearance between the pulley (A) and the pressure plate (B) all the way around. If the clearance is not within specified limits, remove the pressure plate (see «A/C COMPRESSOR CLUTCH OVERHAUL»(ref-333580-S34490653552009072100000) ) and add or remove shims as needed to increase or decrease clearance. Clearance: 0.30-0.60 mm (0.012-0.024 in.) NOTE: The shims are available in three thicknesses: 0.1 mm, 0.3 mm, and 0.5 mm.
4. Measure the resistance of the field coil. If the resistance is not within specifications, replace the field coil (see «A/C COMPRESSOR CLUTCH OVERHAUL»(ref-333580-S34490653552009072100000) ). Field Coil Resistance: 3.9-4.3ohms at 68°F (20°C)

Receiver/Dryer Desiccant Replacement

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

Scheme 85

1. Remove the A/C condenser (see «A/C CONDENSER REPLACEMENT»(ref-333580-S14607131132009072100000) ).
2. Remove the cap (A) from the bottom of the A/C condenser. Remove the O-ring (B) and the desiccant (C).
3. Install the receiver/dryer in the reverse order of removal, and note these items: 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. Install the cap to the specified torque. It is made of plastic and can be easily stripped.