Honda_Element_2003-2006

Heater Core

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section. Also see the IMA system disabling before proceeding with any procedure.
  2.  
  3. Disconnect the negative battery cable and wait for 3 minutes.
  4.  
  5. Place the front wheels in the straight ahead position.
  6.  
  7. Drain the cooling system into a clean container for reuse.
  8.  
  9. In the engine compartment, open the heater valve cable clamp and disconnect the cable from the heater valve arm. Then, turn the heater valve to the fully opened position.
  10.  
  11. Disconnect the heater hoses from the heater core.
  12.  
  13. Remove the heater housing-to-chassis nut.
    NOTE
    When removing the heater housing nut, be careful not to damage or bend the fuel lines, the brake lines, etc.

  14.  
  15. Remove the front center floor console.
  16.  
  17. Remove the glove box
  18.  
  19. Remove the center lower cover.
  20.  
  21. Remove the radio.
  22.  
  23. Remove the steering wheel access cover and disconnect the driver air bag connector.
  24.  
  25. Remove the steering wheel cover and remove the driver air bag.
  26.  
  27. Loosen the steering wheel nut, then use a puller and remove the steering wheel.
  28.  
  29. Remove the steering column covers.
  30.  
  31. Disconnect the cable wheel connectors and remove the cable reel.
  32.  
  33. Disconnect the combination switch and ignition switch connectors.
  34.  
  35. Remove the steering joint pinch bolts.
  36.  
  37. Remove the steering column attaching nuts and remove the steering column.
  38.  
  39. Disconnect the passenger air bag connector.
  40.  
  41. Remove the 3 air bag mounting nuts, then pry carefully with a screwdriver and lift the air bag out of the dashboard.
  42.  
  43. Remove the A pillar trim on both sides.
  44.  
  45. From under and behind the dashboard, disconnect and label all electrical connectors.
  46.  
  47. Remove the driver coin tray.
  48.  
  49. Remove the dashboard attaching bolts (A) and screws (B) as shown.
  50.  
  51. Carefully lift up on the dashboard and disengage it from the holders (C) and (D).
  52.  
  53. Remove the dashboard through the door opening.
  54.  
  55. Discharge and recover the air conditioning system refrigerant.
  56.  
  57. In the engine compartment, remove the refrigerant lines-to-evaporator housing bolts.
  58.  
  59. Separate the lines, discard the grommets and plug the openings to prevent contamination.
  60.  
  61. Disconnect the evaporator housing-s temperature sensor connector.
  62.  
  63. Remove the evaporator housing-to-chassis screws/nut and remove the evaporator housing.
  64.  
  65. Disconnect the mode control motor and the air mix control motor electrical connectors and remove the wiring harness clips and the wiring harness from the heater housing.
  66.  
  67. Remove the heater duct clip, the heater housing-to-chassis nuts and the heater housing.
  68.  
  69. Remove the heater core cover screws and the cover.
  70.  
  71. Remove the heater core pipe clamp screws and the clamp.
  72.  
  73. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. Exploded view of the steering column and related components-Insight



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-Insight



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and housing-Insight

  74.  

To install:

  1. Install the heater core in the heater housing.
  2.  
  3. Install the heater core pipe clamp and the clamp screws.
  4.  
  5. Install the heater core cover and the cover screws.
  6.  
  7. Install the heater housing, the heater housing-to-chassis nuts and the heater duct clip.
  8.  
  9. Install the wiring harness clips and the wiring harness to the heater housing and connect the mode control motor and the air mix control motor electrical connectors.
  10.  
  11. Install the evaporator housing and the evaporator housing-to-chassis screws/nut.
  12.  
  13. Connect the evaporator housing-s temperature sensor connector.
  14.  
  15. Using new grommets, connect the refrigerant lines.
  16.  
  17. In the engine compartment, install the refrigerant lines-to-evaporator housing bolts.
  18.  
  19. Using an assistant, install the instrument panel making sure it is engaged in the holders.
  20.  
  21. Install the driver coin tray.
  22.  
  23. From under and behind the dashboard, reconnect all electrical connectors.
  24.  
  25. Install the A pillar trim on both sides.
  26.  
  27. Place the passenger air bag in the dashboard and tighten 3 mounting nuts.
  28.  
  29. Connect the passenger air bag connector.
  30.  
  31. Install the steering column.
  32.  
  33. Insert the upper end of the steering joint into the steering shaft and line up the bolt hole with the flat on the shaft.
  34.  
  35. Insert the lower end of the joint into the pinion shaft and line up the bolt hole with the groove around the shaft.
  36.  
  37. Install the lower bolt and pull up on the joint to ensure it is securely seated.
  38.  
  39. Install the upper bolt and tighten both bolts to 16 ft. lbs. (22 Nm).
  40.  
  41. Install the steering column covers.
  42.  
  43. Connect the combination switch and ignition switch connectors.
  44.  
  45. Install the cable and center it by rotating it clockwise until it stops. Rotate it counterclockwise about 2 and one half turns until the arrow mark on the reel point straight up.
  46.  
  47. Install the steering wheel on the shaft making sure the wheel hub engages the pins on the cable reel and the tabs of the turn signal canceling sleeve.
  48.  
  49. Install the steering wheel bolt nut and tighten it to 29 ft. lbs. (39 Nm).
  50.  
  51. Install the driver air bag and tighten the bolts to 87 inch lbs. (9.8 Nm).
  52.  
  53. Connect the driver air bag connector and install the steering wheel access cover.
  54.  
  55. Remove the radio.
  56.  
  57. Install the center lower cover.
  58.  
  59. Install the glove box
  60.  
  61. Install the front center floor console.
  62.  
  63. Install the heater housing-to-chassis nut.
  64.  
  65. Connect the heater hoses to the heater core.
  66.  
  67. In the engine compartment, connect the cable to the heater valve arm and close the heater valve cable clamp.
  68.  
  69. Refill the cooling system.
  70.  
  71. Connect the negative battery cable.
  72.  
  73. Evacuate and charge and leak test the air conditioning system refrigerant.
  74.  
  75. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  76.  

 
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