Honda_Odyssey_2001-2006

Heater Core

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Removal & Installation



2001-04 Models

NOTE
Make sure to acquire the anti-theft code for the radio and write down the frequencies for the radio-s preset buttons.

  1. Disconnect the negative battery cable.
    CAUTION
    Wait at least 3 minutes for the air bag to deplete its energy before working on the steering wheel or instrument panel.

  2.  
  3. In the engine compartment, remove the heater valve cable clamp; then, disconnect the heater valve cable and rotate the heater valve to the fully open position.
  4.  
  5. Drain the engine coolant into a clean container for reuse.
  6.  
  7. Disconnect the heater hoses from the heater unit.
  8.  
  9. Remove the heater housing-to-chassis nuts.
  10.  
  11. Remove the center console.
  12.  
  13. Remove the instrument panel.
  14.  
  15. Remove the steering hanger beam mounting bolts and the steering hanger beam.
  16.  
  17. Remove the evaporator housing by performing the following procedure:
    1. Discharge and recover the air conditioning system refrigerant.
    2.  
    3. Remove the refrigerant lines. Discard the O-rings. Plug the openings to prevent contamination.
    4.  
    5. Disconnect the thermostat electrical connector and the wiring harness from the evaporator.
    6.  
    7. Remove the evaporator housing-to-chassis screws, the bolt and nuts.
    8.  
    9. Disconnect the drain hose and remove the evaporator housing.
    10.  

  18.  
  19. Disconnect the electrical connector from the mode control motor.
  20.  
  21. Remove the wiring harness clips from the heater housing.
  22.  
  23. Remove the heater housing-to-chassis nuts and the heater housing.
  24.  
  25. Remove the heater housing screws and separate the housings.
  26.  
  27. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. View of the heater housing, evaporator housing and related components-2001-04



    Click image to see an enlarged view

    Fig. View of the steering hanger beam and related components-2001-04



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, the heater housing and related components-2001-04

  28.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Assemble the housings and install the heater housing screws.
  4.  
  5. Install the heater housing and the heater housing-to-chassis nuts.
  6.  
  7. Install the wiring harness clips to the heater housing.
  8.  
  9. Connect the electrical connector to the mode control motor.
  10.  
  11. Install the evaporator housing by performing the following procedure:
    1. Install the evaporator housing and connect the drain hose.
    2.  
    3. Install the evaporator housing-to-chassis screws, the bolt and nuts.
    4.  
    5. Connect the thermostat electrical connector and the wiring harness to the evaporator.
    6.  
    7. Using new O-rings, install the refrigerant lines.
    8.  
    9. Evacuate and charge the air conditioning system refrigerant.
    10.  

  12.  
  13. Install the steering hanger beam and the steering hanger beam mounting bolts.
  14.  
  15. Install the instrument panel.
    NOTE
    When installing the nuts, be careful not to damage or bend the fuel lines, the brake lines or etc.

  16.  
  17. Install the heater housing-to-chassis nuts.
  18.  
  19. Connect the heater hoses to the heater unit.
  20.  
  21. Refill the cooling system.
  22.  
  23. In the engine compartment, install the heater valve cable clamp; then, connect the heater valve cable.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  28.  

2005-06 Models
  1. Make sure you have the anti-theft codes for the radio and the navigation system, then write down the XM radio channel presets.
  2.  
  3. Make sure the ignition is OFF, then disconnect the negative cable from the battery. Wait at least 3 minutes before proceeding.
  4.  
  5. Recover the refrigerant with a recovery/recycling/charging station.
  6.  
  7. Remove the intake manifold cover. See Intake Manifold Removal and Installation.
  8.  
  9. Remove the bolts and nut, then disconnect the suction line (A) and the receiver line (B) from the evaporator core.

    Click image to see an enlarged view

    Fig. Remove the bolts and nut, then disconnect the suction line (A) and the receiver line (B) from the evaporator core-2005-06 models

  10.  
  11. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown.

    Click image to see an enlarged view

    Fig. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown-2005-06 models

  12.  
  13. When the engine is cool, drain the engine coolant from the radiator.

    Click image to see an enlarged view

    Fig. Drain the engine coolant from the radiator

  14.  
  15. Slide the hose clamps (A) back. Remove the nut and the water valve (B), then disconnect the inlet heater hose (C) and the outlet heater hose (D) from the heater unit. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately.

    Click image to see an enlarged view

    Fig. Slide the hose clamps (A) back. Remove the nut and the water valve (B), then disconnect the inlet heater hose (C) and the outlet heater hose (D) from the heater unit-2005-06 models

  16.  
  17. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines and the brake lines, etc.
    NOTE
    Put on gloves to protect your hands. Take care not to scratch the dashboard and related parts. Take care not to bend the brackets. Use the appropriate tool from the KTC trim tool set to avoid damage when prying components.



    Click image to see an enlarged view

    Fig. Remove the mounting nut from the heater unit-2005-06 models

  18.  
  19. From under the dash, remove the clip (A) and detach the clip (B), release the hook (C) and stud (D), then remove the driver's heater lower cover (E) and passenger's heater lower cover (F).

    Click image to see an enlarged view

    Fig. From under the dash, remove the clip (A) and detach the clip (B), release the hook (C) and stud (D), then remove the driver's heater lower cover (E) and passenger's heater lower cover (F)-2005-06 models

  20.  
  21. Open the beverage holder (A), and remove the screws.

    Click image to see an enlarged view

    Fig. Open the beverage holder (A), and remove the screws-2005-06 models

  22.  
  23. Remove the dashboard center lower cover (A).
    1. Pull out the cover to release the clips (B, C).
    2.  
    3. Disconnect the seat heater connectors (D) and accessory socket connectors (E).

      Click image to see an enlarged view

      Fig. Remove the dashboard center lower cover (A). Pull out the cover to release the clips (B, C). Disconnect the seat heater connectors (D) and accessory socket connectors (E)-2005-06 models

    4.  

  24.  
  25. Remove the screws, then remove the driver's A/C duct (A) from the dashboard (B).

    Click image to see an enlarged view

    Fig. Remove the screws, then remove the driver's A/C duct (A) from the dashboard (B)-2005-06 models

  26.  
  27. Remove the screws, then remove the passenger's A/C duct (A) from the dashboard (B).

    Click image to see an enlarged view

    Fig. Remove the screws, then remove the passenger's A/C duct (A) from the dashboard (B)-2005-06 models

  28.  
  29. Remove the screws, then remove the center A/C duct from the dashboard.
  30.  
  31. Remove the screws, then remove the defogger duct (A) from the dashboard (B).

    Click image to see an enlarged view

    Fig. Remove the screws, then remove the defogger duct (A) from the dashboard (B)-2005-06 models

  32.  
  33. Disconnect the connectors (A) from the blower motor and the power transistor, then remove the wire harness clips (B).

    Click image to see an enlarged view

    Fig. Disconnect the connectors (A) from the blower motor and the power transistor, then remove the wire harness clips (B)-2005-06 models

  34.  
  35. Disconnect the connectors (A) from the mode control motor and the recirculation control motor, then remove the wire harness clips (B) and the connector clip (C).

    Click image to see an enlarged view

    Fig. Disconnect the connectors (A) from the mode control motor and the recirculation control motor, then remove the wire harness clips (B) and the connector clip (C)-2005-06 models

  36.  
  37. Disconnect the connectors from the evaporator sensor and the air mix control motor, then remove the wire harness clips and the wire harness.
  38.  
  39. Remove the drain hose (A), then remove the nuts and the blower-heater unit (B).

    Click image to see an enlarged view

    Fig. Remove the drain hose (A), then remove the nuts and the blower-heater unit (B)-2005-06 models

  40.  
  41. Remove the self-tapping screws, the joint duct (A), and seal (B). Remove the self-tapping screws, then remove the passenger's heater outlet (C), and the heater core cover (D). Remove the self-tapping screws, the heater pipe brackets (E), the grommets (F), and carefully pull out the heater core (G) so you don't bend the inlet and outlet pipes.

    Click image to see an enlarged view

    Fig. Remove the self-tapping screws, the joint duct (A), and seal (B). Remove the self-tapping screws, then remove the passenger's heater outlet (C), and the heater core cover (D). Remove the self-tapping screws, the heater pipe brackets (E), the grommets (F), and carefully pull out the heater core (G)-2005-06 models

  42.  
  43. Install the heater core in the reverse order of removal.
  44.  
  45. Install the heater unit in the reverse order of removal, and note these items:

    Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely.
     
    Refill the cooling system with engine coolant.
     
    Make sure that there is no coolant leakage.
     
    Make sure that there is no air leakage.
     
    If you're installing a new evaporator core, add refrigerant oil (DENSO ND-OIL 8).
     
    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.
     

  46.  
  47. Adjust the heater valve cable.
    1. Set the temperature control dial to Max Cool (Lo) with the ignition switch ON (II).
    2.  
    3. Attach the heater valve cable (B) to the air mix control linkage (C) as shown. Hold the end of the heater valve cable housing against the stop (D), then snap the heater valve cable housing into the cable clamp (A).
      NOTE
      Make sure the ring-end of the cable is pushed all the way to the base of the pin on air mix control linkage.



      Click image to see an enlarged view

      Fig. Attach the heater valve cable (B) to the air mix control linkage (C) as shown. Hold the end of the heater valve cable housing against the stop (D), then snap the heater valve cable housing into the cable clamp (A)-2005-06 models

    4.  
    5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A).

      Click image to see an enlarged view

      Fig. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A)-2005-06 models

    6.  

  48.  
  49. Reset the power window control unit:
    1. Using the HDS:

      Connect the HDS to the vehicle's DLC.
       
      Turn the ignition switch ON (II), then enter the vehicle's VIN and mileage at the prompts.
       
      Select ''BODY ELECTRICAL'' from the ''System Selection'' menu.
       
      From the ''BODY ELECTRICAL SYSTEM SELECT'' menu, select ''Power Windows''.
       
      From the ''MODE'' menu, select ''Adjustments''.
       
      From the ''ADJUSTMENT'' menu, select ''WINDOW P RESET'' for driver's side window.
       
      Follow the prompts on the screen.
       
      Confirm that the power window control unit is reset by using the driver's window AUTO UP and AUTO DOWN function.
       

    2.  
    3. Without the HDS:
      NOTE
      The next 4 steps must be done within 5 seconds of each other.



      Turn the ignition switch ON (II).
       
      Move the driver's window all the way down by using the driver's window DOWN switch.
       
      Open the driver's door.
       



      Turn the ignition switch OFF.
       
      Push and hold the driver's window DOWN switch.
       
      Turn the ignition switch ON (II).
       
      Release the driver's window DOWN switch.
       
      Repeat these 4 steps three more times.
       
      Wait 1 second.
       
      Confirm that AUTO UP and AUTO DOWN do not work. If AUTO UP and DOWN work, go back to the first step.
       
      Move the driver's window all the way down by using the driver's window DOWN switch.
       
      Pull up and hold the driver's window UP switch until the window reaches the fully closed position, then continue to hold the switch for 1 second.
       
      Confirm that the power window control unit is reset by using the driver's window AUTO UP and AUTO DOWN function.
       
      If the window still does not work in AUTO, repeat the procedure several times, paying close attention to the 5 second time limit between steps.
       

    4.  

  50.  
  51. Enter the anti-theft codes for the radio and the navigation system, then enter the XM radio channel presets.
  52.  

 
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