AC Evaporator

This procedure involves removing the dashboard and HVAC unit to replace the AC evaporator core in the 2018-2024 Honda Accord with 1.5L turbo engine.

Warnings

Tools required

Parts

• AC evaporator core × 1 — 80211-TVA-A01 or equivalent
• Expansion valve × 1 — Use OEM specification
• AC line O-rings × 1 — Use OEM O-ring kit
• Receiver drier × 1 — Replace when system is opened
• PAG 46 compressor oil × 1 — Honda 08798-9002
• R-1234yf refrigerant × 1 — 19.4 oz capacity

Fluids

• Honda Type 2 Coolant (Blue) — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and wait minimum 3 minutes for SRS system discharge
3. Recover all AC refrigerant using certified AC recovery machine and record amount removed
4. Drain engine coolant to below heater core level into clean container for reuse
5. Remove engine cover (pull upward to release clips)
6. Remove both front floor mats and protect interior with seat covers

Procedure

1. 1

   Disconnect AC lines at firewall
   Locate AC lines at firewall on passenger side. Using flare nut wrenches, disconnect the liquid line and suction line fittings. Cap all open lines immediately to prevent moisture entry. Remove and discard all O-rings.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
2. 2

   Remove steering wheel and column covers
   Remove driver airbag module by accessing clips on sides of steering wheel. Disconnect airbag connector and remove airbag. Mark steering wheel position on shaft. Remove steering wheel bolt and use steering wheel puller to remove wheel. Remove upper and lower steering column covers by removing screws.
   ⚠️Never strike steering wheel or column while airbag connector is attached. Always place removed airbag face-up on clean surface away from work area.
3. 3

   Remove instrument cluster and center console
   Remove gauge cluster trim panel using trim tools. Remove four cluster mounting screws and pull cluster forward. Disconnect all electrical connectors behind cluster. Remove center console by removing screws in cup holders, under armrest, and at front. Disconnect all electrical connections including USB ports and 12V socket.
4. 4

   Remove dashboard side panels and lower panels
   Remove both A-pillar trim panels by pulling outward from top. Remove both front door sill plates. Remove both dashboard side cover panels. Remove driver and passenger lower dashboard panels by removing screws and releasing clips. Disconnect hood release cable on driver side.
5. 5

   Disconnect main dashboard wiring and controls
   Disconnect all electrical connectors accessible from under dashboard including: climate control module, radio antenna, all HVAC actuators, passenger airbag connector, glove box light, and any remaining connectors. Disconnect heater hoses at firewall (be prepared for coolant spillage).
   ⚠Have drain pan ready when disconnecting heater hoses as residual coolant will drain from lines.
6. 6

   Remove dashboard mounting bolts
   Locate and remove all dashboard mounting bolts: two at each end near A-pillars, four along top edge under defroster vents, two at center support bracket, and two at bottom near transmission tunnel. Carefully pull dashboard rearward to disengage from firewall and remove from vehicle with assistant.
   ⚠Dashboard is bulky and heavy. Use second person to support passenger side during removal to prevent damage.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
7. 7

   Remove blower motor and housing
   With dashboard removed, access to HVAC unit is now clear. Disconnect blower motor electrical connector. Remove blower motor mounting screws and remove blower motor assembly from HVAC case. Remove any remaining brackets or covers from HVAC unit.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)
8. 8

   Separate HVAC case halves
   Remove all screws securing upper and lower HVAC case halves together. Carefully note position of all actuator linkages and mode doors before separation. Gently separate case halves. The evaporator core will be visible in lower case half.
   ℹ️Take detailed photos of actuator positions and linkage routing before disturbing. Incorrect reassembly will cause improper air distribution.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)
9. 9

   Remove expansion valve and evaporator
   Disconnect expansion valve from evaporator core inlet. Remove expansion valve mounting hardware and remove valve (discard and replace with new). Carefully lift evaporator core from lower case half. Remove any remaining foam seals or insulation (these must be transferred to new evaporator).
   ⚠Handle evaporator carefully to avoid bending fragile aluminum fins. Bent fins reduce cooling efficiency.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
10. 10

    Install new evaporator and expansion valve
    Transfer all foam seals and insulation to new evaporator core in exact positions as removed. Place new evaporator into lower HVAC case half ensuring proper seating. Install new expansion valve with new O-rings coated in PAG oil. Add 2 oz of PAG 46 oil through expansion valve port to replenish system oil lost with old evaporator.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
11. 11

    Reassemble HVAC case
    Verify all mode door linkages are in correct position. Carefully align upper and lower HVAC case halves ensuring no wiring or linkages are pinched. Install all case screws in correct locations and tighten evenly. Reinstall blower motor assembly and reconnect electrical connector.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)

    Cover Screws10 Nm (8 lb-ft)
12. 12

    Reinstall dashboard assembly
    With assistant, position dashboard assembly and align with mounting points. Install all mounting bolts finger-tight first, then torque to specification working from center outward. Reconnect all electrical connectors, heater hoses, and hood release cable. Verify all connections are secure.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
13. 13

    Reinstall interior components
    Reinstall lower dashboard panels, side panels, door sills, and A-pillar trim. Reinstall center console and connect all electrical connectors. Reinstall instrument cluster and trim panel. Reinstall steering column covers, steering wheel (aligning marks made during removal), and driver airbag module.
14. 14

    Connect AC lines and install receiver drier
    Install new receiver drier (required when system has been opened). At firewall, install new O-rings coated with PAG oil on both liquid and suction line fittings. Connect AC lines and torque fittings to specification. Ensure proper seating before applying torque.
    ⚠O-rings must be coated with PAG oil and fittings must be clean. Cross-threading or debris will cause immediate system failure.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
15. 15

    Evacuate and recharge AC system
    Reconnect negative battery terminal. Refill coolant system with Honda Type 2 coolant and bleed air. Connect AC vacuum pump and evacuate system to 500 microns for minimum 45 minutes. System must hold vacuum for 30 minutes without rise. Recharge system with 19.4 oz of R-1234yf refrigerant using refrigerant scale for accuracy. Start engine and verify AC operation.
    ⚠Overcharging AC system will cause poor cooling and potential compressor damage. Use scale to measure exact refrigerant amount.

Reassembly

1. Torque all fasteners to specifications using torque wrench
2. Verify all electrical connectors are fully seated with audible clicks
3. Confirm all trim panels and covers are properly aligned before pressing clips into place
4. Test all dashboard functions including HVAC controls, gauge cluster, and switches before completing job

Verification

• Start engine and verify all warning lights clear after SRS system reset
• Test all HVAC modes (defrost, floor, vent, bi-level) and verify proper air distribution from all vents
• Set AC to maximum cold and verify vent temperature reaches 38-42°F within 5 minutes
• Inspect all AC line fittings for signs of refrigerant oil seepage indicating leaks
• Verify blower motor operates smoothly at all speed settings without unusual noise
• Check engine coolant level after engine reaches operating temperature and top off if needed
• Test drive vehicle and verify no rattles or abnormal sounds from dashboard area

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