Part One
Heater Unit/Core Removal and Installation
*These tools are available through the Honda Tool and Equipment Program; call 888-424-6857
Installation
CAUTION:
* Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
* Be careful when connecting service equipment.
* Do not breathe refrigerant or vapor.
* Do not operate the leak detector near flammable vapors. Its sensor operates at high temperatures, and could ignite the vapors, resulting in personal injury and/or damage to the equipment.
SRS components are located in this area. Review the SRS component locations Locations and the precautions and procedures Service and Repair before doing repair or servicing.
NOTE:
* If an accidental system discharge occurs, ventilate the work area before resuming service.
* Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
* Check the system for leaks using an R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better.
* 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 for HFC-134a 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.
* Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely.
* Make sure that there is no coolant leakage.
* Make sure that there is no air leakage.
1. Heater Core
1. Carefully install the heater core (A) without bending the lines.
2. Install the heater pipe bracket (B).
3. Install the grommet (C).
2. Expansion Valve Bracket
1. Install the expansion valve bracket (A).
3. Evaporator Core
1. Install the plate (A).
2. Carefully install the evaporator core (B) without bending the lines.
4. Expansion Valve Cover
1. Install the new seal (A) and the expansion valve cover (B).
2. Install the connector clip (C).
5. Passenger's Air Mix Control Motor (Climate Control)
1. Align the passenger's air mix control motor (A) with the gear, then install the motor.
2. After installation, make sure the motor runs smoothly.
6. Heater Core Cover
1. Install the heater core cover (A).
7. Blower Unit
1. Install the blower unit (A).
8. A/C Wire Harness
1. Connect the air mix control motor connector (A).
2. Install the harness clips (B).
3. Connect the evaporator temperature sensor connector (A).
4. Connect the recirculation control motor connector (B).
5. Connect the mode control motor connector (C).
6. Install the harness clips (D).
7. With climate control: Connect the passenger's air mix control motor connector (A).
8. Connect the power transistor connector (B).
9. Connect the blower motor connector (C).
10. Install the harness clip (D).
9. Passenger's Heater Duct
1. Install the passenger's heater duct (A).
10. Blower-Heater Unit
1. Install the blower-heater unit (A).
2. Connect the drain hose (B).
3. Connect the engine compartment wire harness connector (A).
11. Dashboard/Steering Hanger Beam
Special bolt tightening on passenger's side
NOTE:
* Make sure the collar bolts (A) turn easily by hand in the fixed space adjusters (B). Tighten the collar bolts by hand until they engage the fixed space adjusters before reinstalling the dashboard.
* Before reinstalling the dashboard, screw the special bolts (C) into the collar bolts, and check that they turn together. If they do not turn together, replace the special bolts.
* After setting the dashboard/steering hanger beam in the body, install all of the mounting bolts but do not tighten them. First tighten the driver's side bracket bolts to the specified torque. Next, tighten the special bolts to turn the collar bolts. As you tighten the bolts, the collar bolts screw out of the fixed space adjuster until they contact the body. Continue tightening the special bolts to the specified torque.
1. Install the dashboard upper side cover (A). Make sure the hooks (B) snap into place securely.
2. Install the dashboard/steering hanger beam (A).
3. Install the bolts (A, B).
4. Install the special bolts (A).
5. From under the dash, connect the connectors (A).
6. Install the bolts (B, C), and install the ground bolt (D) with a TORX T30 bit.
NOTE: Apply medium strength liquid thread lock to the mounting bolts (C) before installation.
7. From under the dash, connect the connectors (A), and install the harness clips (B).
8. With climate control: Connect the aspirator hose (A).
9. Connect the connector (B).
10. From under the dash, install the nut (A) and the bolt (B).
11. From under the dash, connect the connectors (A).
Driver's side
Passenger's side
12. At the A-pillar, connect the connector(s) (A).
12. Steering Column
1. Install the steering column (A).
NOTE: Do not release the lock lever until the steering column is installed. If the lock lever is released before installation, adjust the steering column after installation.
2. Loosely tighten the attaching nuts and bolts.
3. Tighten the attaching nuts and bolts to the specified torque in the sequence shown.
4. Install the wire harness clips (B) to the steering column.
5. Connect the connectors (C) to the ignition switch (D).
13. Steering Column Lower Slide Shaft - Release
1. Cut the wire (A).
14. Steering Joint - Reconnection
1. Place the rack in the straight ahead driving position.
2. Slip the lower end of the steering joint (A) onto the pinion shaft (B).
NOTE:
* Pinion shaft with center guide: Install the steering joint by aligning the center guide (C).
* Pinion shaft without center guide: Position the steering column by aligning the gap (D) within the angle.
3. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft.
4. Loosely install the steering joint bolt (C).
5. Be sure that the joint bolt is securely in the groove in the pinion shaft.
6. Pull on the steering joint to make sure that the steering joint is fully seated.
7. Tighten the steering joint bolt to the specified torque.
15. Steering Joint Cover
1. Install the steering joint cover (A).
16. Combination Switch Body Assembly
1. Install the combination switch body assembly (A).
2. Tighten three screws (B) in the sequence shown.
3. Connect the connectors (A).
4. Connect the connectors (A).
5. Install the clip (B).
17. Lower Column Cover
1. Push in on the lower column cover just above ignition switch opening (A) to engage the column cover with the locking tab (B).
2. Install the lower column cover (A), then install the screw (B).
3. Install the screws (A) securing the lower column cover (B) from the front side.
18. Upper Column Cover
1. Install the upper column cover (A).
2. Install the dashboard meter visor blind cover (A). Make sure the clips (B) and the hook (C) snap into place securely.
19. Steering Wheel Assembly
1. Make sure the front wheels are pointing straight ahead.
2. Center the cable reel (A). Do this by first rotating the cable reel clockwise until it stops.
3. Rotate the cable reel counterclockwise about three full turns. The arrow mark (B) on the cable reel label should point straight up.
4. Position the steering wheel hub (A) so that it engages the pin (B) of the cable reel.
5. Install the steering wheel (C) on to the steering column shaft.
NOTE: Do not tap on the steering wheel or the steering column shaft when installing the steering wheel.
6. Install the steering wheel bolt (A), and tighten it to the specified torque.
7. Connect the connector (B).
8. Make sure the wire harness is routed and fastened properly.
20. Driver's Airbag
NOTE: If you are replacing a deployed driver's airbag, inspect the cable reel for heat damage. If there is any damage, replace the cable reel.
1. Place the driver's airbag (A) in the steering wheel.
2. Tighten the new TORX bolts using a TORX T30 bit.
NOTE: Make sure the clearance (B) between the steering wheel and the horn pad is the specified value.
3. Connect the driver's airbag inflator connector (A) on the cable reel harness.
4. Connect the horn switch connector (B).
NOTE: After reconnecting the negative cable to the battery, make sure the horn works properly.
5. Install the access panel (C).
21. Kick Panel - Both Sides
Driver's side
Passenger's side
1. Install the driver's side kick panel (A) and the passenger's side kick panel (B). Make sure the clips (C) snap into place securely.
2. Install the front door opening seal (D).
22. Driver's Dashboard Lower Cover
1. Connect the connector (A), then install the driver's dashboard lower cover (B). Make sure the clips (C) snap into place securely.
23. Driver's Dashboard Panel Assembly
1. Connect the connector (A), then install the driver's dashboard panel assembly (B). Make sure the clips (C) snap into place securely.
24. Passenger's Dashboard Undercover
1. Install the passenger's dashboard undercover (A). Make sure the clips (B) snap into place securely, and the pins (C) into the holder (D) securely.
25. Driver's Dashboard Undercover
1. Install the driver's dashboard undercover (A). Make sure the clip (B) snap into place securely, and the pin (C) into the holder (D) securely.
2. Turn the lock knob (E) 90 °.