Honda Accord/Prelude 1984-1995 Repair Guide

Evaporator Core

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REMOVAL & INSTALLATION



1984-89 Accord

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Safely discharge the air conditioning system using the proper recovery/recycling equipment.
  4.  
  5. Disconnect the line and hose from the evaporator at the firewall in the engine compartment. Cap the fittings immediately to keep out dirt.
  6.  
  7. Remove the grommets from the firewall.
  8.  
  9. Remove the glove box and its frame.
  10.  
  11. At the evaporator, loosen the right sealing band; slide it to the left.
  12.  



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Fig. Fig. 1: Evaporator case mounting on 1984-85 Accords

  1. Remove the screw from the air door diaphragm. Leave the diaphragm attached to the arm. Remove the blower mounting bolts and remove the blower assembly.
  2.  



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Fig. Fig. 2: Evaporator mounting on 1986-89 Accords

  1. Remove the left seal band and disconnect the wiring. Remove the 3 bolts and remove the evaporator case.
  2.  
  3. To disassemble the case, remove the screw and clips from the housing.
  4.  
  5. Carefully separate the halves of the case. Remove the sensing bulb from the fins of the evaporator.
  6.  
  7. Remove the expansion valve, evaporator core or thermostat as necessary.
  8.  

To install:
  1. If a new evaporator is being installed, add 1 fl. oz. (30 cc) of refrigerant oil to the new unit on 1984-85 models or 2 fl. oz. (60 cc) on 1986-89 models.
  2.  
  3. Reassemble the case components as necessary. Install the sensing bulb in its original location. Reassemble the upper and lower case halves, making sure there are no gaps in the case.
  4.  
  5. Install the evaporator assembly and install the retaining bolts. Don't forget to attach the evaporator drain hose and route it out of the car.
  6.  
  7. Install the left sealing band. Connect the wiring.
  8.  
  9. Install the blower assembly.
  10.  
  11. Remount the air door diaphragm and tighten the screw.
  12.  
  13. Install the right seal band and tighten it. Double check each band; they should be square and tight.
  14.  
  15. Install the glove box and frame.
  16.  
  17. Install the grommets. Coat the contact surfaces with sealant before installation.
  18.  
  19. Connect the line and hose to the evaporator fittings. Replace the O-rings with new ones. Tighten the receiver line to 12 ft. lbs. (16 Nm) and the suction hose to 22 ft. lbs. (30 Nm).
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Evacuate and recharge the air conditioning system.
  24.  

1990-95 Accord

See Figures 3 and 4

  1. Disconnect the negative battery cable. If so equipped, disable the Supplemental Restraint System (SRS).
  2.  
  3. Safely discharge the air conditioning system using the proper recovery/recycling equipment.
  4.  
  5. Disconnect the line and hose from the evaporator fittings at the firewall in the engine compartment. Cap the fittings immediately to keep out dirt.
  6.  
  7. Remove the glove box and its frame.
  8.  
  9. If equipped, loosen and remove the two bands at the evaporator.
  10.  
  11. Disconnect the thermostat wire.
  12.  
  13. Remove the drain hose. Remove the retaining nuts/bolts and remove the evaporator.
  14.  



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Fig. Fig. 3: Evaporator mounting on 1990-93 Accords

  1. Remove the sensing bulb from the evaporator fins.
  2.  



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Fig. Fig. 4: Evaporator mounting on 1994-95 Accords

  1. Remove the screws and clips holding the housing.
  2.  
  3. Carefully separate the housings and remove the covers.
  4.  
  5. Remove the expansion valve, evaporator core or thermostat as necessary.
  6.  

To install:
  1. If a new evaporator is being installed, add 5 / 6 fl. oz. (25 cc) of refrigerant oil to the new unit on 1990-93 models or 1 1 / 3 fl. oz. (40 cc) on 1994-95 models. On 1990-93 models with Nippodenso compressors, use ND Oil 9, on Hadsys compressors use Hermetic 90 PX refrigerant oil. On 1994-95 models with Nippodenso compressors, use ND Oil 8, on Hadsys compressors use Daphne Hermetic S10X refrigerant oil. These refrigerant oils are usually available at your Honda dealer.
  2.  
  3. Reassemble the case components as necessary. Install the sensing bulb in its original location. Reassemble the upper and lower case halves, making sure there are no gaps in the case.
  4.  
  5. Install the evaporator assembly and install the retaining nuts/bolts. Don't forget to attach the evaporator drain hose and route it out of the car.
  6.  
  7. Connect the thermostat wire.
  8.  
  9. If equipped, install the bands.
  10.  
  11. Install the glove box and frame.
  12.  
  13. Connect the receiver line and suction pipe with new O-rings. Tighten the receiver line to 12 ft. lbs. (17 Nm) on 1990-93 models or 10 ft. lbs. (13 Nm) on 1994-95 models. Tighten the suction line to 23 ft. lbs. (32 Nm).
  14.  
  15. If applicable, enable the SRS.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Evacuate and recharge the air conditioning system.
  20.  

1984-91 Prelude

See Figures 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Safely discharge the air conditioning system using the proper recovery/recycling equipment.
  4.  
  5. Disconnect the line and hose from the evaporator fittings at the firewall in the engine compartment. Cap the fittings immediately to keep out dirt.
  6.  
  7. On 1984-87 models, remove the hose grommets from the firewall. Remove both lower dash panels.
  8.  
  9. On 1988-91 models, remove the glove box.
  10.  
  11. Disconnect the wiring from the blower and the thermostat. Free the wiring from the clips.
  12.  
  13. On 1984-87 models, remove the sealing band from between the blower and evaporator, then remove the blower assembly.
  14.  
  15. Remove the evaporator case mounting nuts and bolts, then remove the assembly from the vehicle.
  16.  



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Fig. Fig. 5: Evaporator assembly used on 1984-87 Preludes



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Fig. Fig. 6: Evaporator assembly used on 1988-91 Preludes

  1. Remove the sensing bulb from the evaporator fins.
  2.  
  3. Remove the screws and clips securing the housing. Carefully separate the housings and remove the covers.
  4.  
  5. Remove the expansion valve, evaporator core or thermostat as necessary.
  6.  

To install:
  1. If a new evaporator is being installed, add 1 fl. oz. (30 cc) of refrigerant oil to the new unit.
  2.  
  3. Reassemble the case components as necessary. Install the sensing bulb in its original location. Reassemble the upper and lower case halves, making sure there are no gaps in the case.
  4.  
  5. Install the evaporator case assembly and install the retaining nuts. Don't forget to attach the evaporator drain hose and route it out of the car.
  6.  
  7. Connect the thermostat wire or blower wire harness.
  8.  
  9. Install the glove box and blower motor as necessary.
  10.  
  11. Install the sealing bands. Check their positioning for an air-tight seal.
  12.  
  13. On 1984-87 models, install the lower dash panels and the grommets at the firewall.
  14.  
  15. Connect the receiver line and suction hose. Tighten the receiver line to 12 ft. lbs. (17 Nm) and the suction line to 23 ft. lbs. (32 Nm).
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Evacuate and recharge the air conditioning system.
  20.  

1992-95 Prelude

See Figures 7, 8, 9 and 10

  1. Disconnect the battery cables, then disable the Supplemental Restraint System (SRS).
  2.  
  3. Safely discharge the air conditioning system using the proper recovery/recycling equipment.
  4.  
  5. Remove the bolt securing the receiver line and the nut securing the suction line to the evaporator. Cap the lines to prevent the entry of dirt and moisture.
  6.  
  7. Remove the right side speaker from the dashboard.
  8.  
  9. Remove the instrument panel visor and black face panel. These are secured by a series of screws.
  10.  
  11. Remove the screws securing the glove box, then remove it from the vehicle.
  12.  
  13. Remove the mounting and adjusting nuts securing the passenger's air bag. Carefully lift the air bag assembly out of the dashboard.
  14.  



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Fig. Fig. 7: Carefully remove the air bag from the vehicle

  1. Remove the bolts securing the passenger's air bag frame and the screws securing the air bag bracket. Remove the assemblies from the vehicle.
  2.  



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Fig. Fig. 8: Remove the air bag frame ...



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Fig. Fig. 9: ... and bracket

  1. Unplug the electrical connector from the thermostat.
  2.  
  3. Remove the nuts/bolts securing the evaporator case, then remove the assembly from the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 10: Evaporator mounting on 1992-95 Preludes

  1. To disassemble the case, remove the screw and clips from the housing.
  2.  
  3. Carefully separate the halves of the case. Remove the sensing bulb from the fins of the evaporator.
  4.  
  5. Remove the expansion valve, evaporator core or thermostat as necessary.
  6.  

To install:
  1. If a new evaporator is being installed, add 1 fl. oz. (30 cc) of refrigerant oil to the new unit.
  2.  

Use only refrigerant oil made expressly for use with R-134a systems. Do not use R-12 refrigerant, oil or components on R-134a systems and vice versa. Expensive system damage will result, as they are not compatible.

  1. Reassemble the case components as necessary. Install the sensing bulb in its original location. Reassemble the upper and lower case halves, making sure there are no gaps in the case.
  2.  
  3. Install the evaporator assembly and install the retaining nuts/bolts. Don't forget to attach the evaporator drain hose and route it out of the car.
  4.  
  5. Engage the electrical connector for the thermostat.
  6.  
  7. Install the air bag bracket. Tighten the screws until snug.
  8.  
  9. Install the air bag frame using new bolts. Tighten them to 7 ft. lbs. (10 Nm).
  10.  
  11. Carefully position the air bag in the dashboard. Loosen the two mounting nuts on the L-bracket.
  12.  
  13. Push the air bag assembly downwards and install the adjusting nuts. Turn them until they touch the lower part of the air bag assembly.
  14.  
  15. Install four new mounting nuts and tighten them to 7 ft. lbs. (10 Nm). Tighten the two nuts on the L-bracket to the same specification.
  16.  
  17. Install the glove box and the dash trim panels. Install the right side speaker.
  18.  
  19. Connect the suction and receiver lines with new O-rings. Lightly lubricate the O-rings with clean refrigerant oil, then tighten the nut/bolt to 7 ft. lbs. (10 Nm).
  20.  
  21. Enable the SRS, then connect the battery cables.
  22.  
  23. Evacuate and recharge the air conditioning system.
  24.  

 
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