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Front Evaporator Core Replacement

WARNING: This page is about a different car, the 2011 Honda Pilot, 2010 Honda Pilot, and 2009 Honda Pilot. However, it is still accessible from the selected car via links, so may be relevant.
  1. Recover the refrigerant with a recovery/recycling/charging station, (see REFRIGERANT RECOVERY  )
  2. Remove the bolts.
    Fig 1: Bolts With Torque Specification
    G05963766Courtesy of AMERICAN HONDA MOTOR CO., INC.
  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).
    Fig 2: Front Receiver Line, Front Suction Line & O-Rings With Torque Specifications
    G05963767Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Remove the blower unit (see BLOWER UNIT REMOVAL/INSTALLATION  ).
  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).
    Fig 3: Identifying Front Power Transistor Connector, Harness Clip, Expansion Valve Cover & Seal
    G05963768Courtesy of AMERICAN HONDA MOTOR CO., INC.
  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).
    Fig 4: Identifying Inlet & Outlet Pipes, Expansion Valve & Front Evaporator Core
    G05963769Courtesy of AMERICAN HONDA MOTOR CO., INC.
  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  ).
    • 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  ).
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