AC Evaporator

Complete replacement of the AC evaporator core, requiring full dashboard and HVAC unit removal to access the evaporator case mounted behind the instrument panel.

Warnings

Tools required

Parts

• AC Evaporator Core × 1 — 80215-TBA-A01 or equivalent
• Expansion Valve × 1 — Replace with evaporator
• AC O-Ring Kit × 1 — Use Honda genuine O-rings
• Receiver Drier/Accumulator × 1 — Replace when system is opened
• PAG Oil × 1 — PAG-46 for R-134a or POE for R-1234yf
• Evaporator Temperature Sensor × 1 — Reuse if undamaged
• HVAC Case Foam Seal × 1 — Use OEM specification
• Dashboard Clips and Fasteners × 1 — Replacement for broken clips

Fluids

• R-134a or R-1234yf Refrigerant (per vehicle spec) — 0.5 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 approved recovery machine and document amount removed
4. Allow engine to cool completely if recently operated
5. Remove both front seats to provide working space and protect from damage
6. Cover steering wheel and center console with protective material to prevent scratches
7. Organize labeled containers or bags for fasteners by location (take photos of each stage)

Procedure

1. 1

   Disconnect AC Lines at Firewall
   From engine bay, locate AC line connections at firewall near passenger side. Disconnect the liquid line and suction line fittings using appropriate wrenches. Immediately cap all open fittings to prevent moisture and debris entry. Note position and orientation of lines for reinstallation.
   ⚠Ensure AC system is fully recovered before disconnecting lines. Residual pressure can spray oil.
   Torque spec

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

   Remove Lower Dashboard Panels and Console
   Remove lower driver and passenger side dashboard panels using trim tools. Remove center console starting from rear and working forward: remove cup holder insert, console side panels, shift boot (automatic), and console mounting screws. Disconnect all electrical connectors for USB ports, power outlets, and shifter (if applicable). Remove console as complete assembly.
3. 3

   Remove Steering Column Covers and Instrument Cluster
   Remove upper and lower steering column covers by releasing retaining clips. Remove instrument cluster bezel trim. Disconnect instrument cluster electrical connector and carefully remove cluster assembly. Lower steering column to lowest position and tilt fully forward to provide clearance.
4. 4

   Disconnect Dashboard Electrical Connectors
   Systematically disconnect all dashboard electrical connectors including: blower motor connector, climate control module, passenger airbag connector (yellow), radio/navigation unit, hazard switch, all HVAC servo motors, evaporator temperature sensor, and any additional cabin sensors. Label or photograph each connection location.
   ⚠️Handle airbag connectors with care. Do not probe or test airbag circuits with power connected.
5. 5

   Remove Dashboard Cross Beam Bolts
   Locate and remove dashboard mounting bolts: two bolts at each A-pillar (driver and passenger sides), bolts at center support bracket, and bolts securing dashboard to transmission tunnel. On models with advanced safety features, carefully disconnect any camera or radar module connections. Remove dashboard support brackets.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
6. 6

   Remove Dashboard Assembly
   With assistant supporting passenger side, carefully pull dashboard rearward to disengage from firewall. Verify all electrical connectors are disconnected and no wiring is trapped. Lift and remove dashboard as complete assembly. Place on protected surface away from work area.
   ⚠Dashboard is bulky and heavy. Use two people to prevent damage to components or windshield.
7. 7

   Access and Remove HVAC Unit
   With dashboard removed, locate HVAC unit mounted to firewall. Disconnect blower motor electrical connector if not already done. Remove HVAC unit mounting bolts/nuts from both passenger and driver sides. Disconnect any remaining servo motor connectors and temperature sensor wiring. Note refrigerant line pass-through locations at firewall.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
8. 8

   Remove HVAC Unit from Vehicle
   Carefully guide AC lines through firewall opening while pulling HVAC unit into cabin. Tilt and rotate unit as needed to clear steering column support and other obstructions. Remove HVAC unit completely from vehicle and place on clean workspace.
9. 9

   Disassemble HVAC Case
   Remove blower motor assembly if still attached. Remove all case cover screws around perimeter of HVAC unit. Separate upper and lower case halves carefully, noting position of mode doors and linkages. Disconnect evaporator temperature sensor from old evaporator. Remove servo motors if they obstruct case separation.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)

   Evaporator Case Screws5 Nm (4 lb-ft)
10. 10

    Remove Old Evaporator and Expansion Valve
    Disconnect expansion valve from evaporator. Remove evaporator mounting brackets or clips. Carefully lift evaporator core from case, noting orientation and position. Remove expansion valve from refrigerant lines, noting inlet and outlet positions. Inspect case for debris, leaves, or signs of moisture damage. Clean case interior thoroughly.
    ℹ️Check evaporator fins for cause of failure (corrosion, road salt, debris) to prevent repeat failure.
    Torque spec

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

    Install New Expansion Valve
    Install new O-rings on expansion valve inlet and outlet, lightly coating with appropriate PAG oil (PAG-46 for R-134a or POE for R-1234yf). Install expansion valve to refrigerant lines and torque to specification. Verify correct orientation with thermal sensing bulb positioned properly.
    ⚠Use only refrigerant oil compatible with vehicle's refrigerant type. Mixing oil types can damage AC system.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
12. 12

    Install New Evaporator Core
    Add specified amount of PAG oil to new evaporator (typically 30-40ml, check service manual for exact amount). Install new evaporator into case in same orientation as original. Install evaporator temperature sensor to new evaporator. Secure evaporator mounting brackets or clips. Install new foam seals around evaporator to prevent air bypass.
13. 13

    Reassemble HVAC Case
    Verify all mode doors and linkages are properly positioned. Join upper and lower case halves, ensuring proper alignment. Install all evaporator case screws and torque to specification. Reinstall servo motors if removed. Verify all case connections are sealed and no gaps exist that could cause air leaks.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)

    Cover Screws10 Nm (8 lb-ft)
14. 14

    Reinstall HVAC Unit to Vehicle
    Guide HVAC unit back into vehicle while carefully threading AC lines through firewall opening. Position unit against firewall and install mounting bolts. Torque mounting bolts to specification. Reconnect blower motor and all servo motor electrical connectors. Reconnect evaporator temperature sensor connector.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
15. 15

    Reinstall Dashboard Assembly
    With assistant, position dashboard assembly and carefully guide into position against firewall. Install dashboard mounting bolts at A-pillars, center support, and transmission tunnel. Torque to specification. Reconnect all electrical connectors in reverse order of removal, including passenger airbag (yellow connector last). Reinstall instrument cluster, steering column covers, console, and all trim panels.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
16. 16

    Connect AC Lines at Firewall
    Install new O-rings on AC line fittings, coating lightly with appropriate PAG oil. Connect liquid line and suction line to evaporator connections at firewall. Torque AC line fittings to specification. Verify connections are properly seated and aligned.
    ⚠Cross-threading AC fittings will cause leaks. Thread by hand first to ensure proper engagement.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
17. 17

    Vacuum and Recharge AC System
    Connect vacuum pump to AC service ports. Evacuate system for minimum 45 minutes to remove all moisture and air. System should hold vacuum for 30 minutes without loss. If vacuum holds, recharge system with correct refrigerant type and amount (refer to underhood label, typically 14-18 oz). Add refrigerant oil if system capacity requires additional oil beyond what was added to components.
    ⚠Insufficient vacuum time will leave moisture in system, leading to expansion valve freezing and compressor damage.

Reassembly

1. Reinstall front seats and torque mounting bolts to specification
2. Reconnect negative battery terminal
3. Perform climate control system initialization procedure using scan tool if required
4. Clear any diagnostic trouble codes related to disconnected sensors or modules
5. Verify all dashboard functions operate correctly: lights, HVAC controls, gauges, radio

Verification

• Start engine and verify AC compressor engages when AC is turned on
• Check for cold air output from all vents within 2-3 minutes of operation
• Verify temperature control adjusts air temperature smoothly across full range
• Inspect all AC line connections at firewall for signs of refrigerant leakage using leak detector
• Check evaporator drain tube under vehicle produces condensation during AC operation
• Verify no unusual odors from HVAC system during operation
• Test all dashboard functions: instrument cluster, radio, HVAC controls, switches
• Verify no airbag warning lights remain illuminated after system check
• Monitor AC system performance over several drive cycles to confirm proper operation
• Verify cabin temperature reaches desired setpoint and maintains consistently

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