INSTALLATION INSTRUCTIONS - PDF Free Download

INSTALLATION INSTRUCTIONS Accessry Applicatin Publicatins N. All 24039 AIR CONDITIONER ACCORD (DX) 4-DOOR Issue Date SEP 2002 What s New The A/C kit and instructins fr the 2003 Accrd are all new. Fllw these instructins carefully. TOOLS AND SUPPLIES REQUIRED Open-end wrench set 90-Degree hk-shaped tl Screwdrivers Scket wrench set 1/2" Drive breaker bar Trque wrench Refrigerant il (R12 mineral il r R134a PAG il) Fender cvers, flr mats, and seat cvers HFC-134a refrigerant recvery/recycling/charging statin Glves Eye prtectin (face shield, safety gggles, etc.) Electrnic leak detectr NOTICE Use nly HFC-134a in this system; d nt use CFC 12 Refrigerant; d nt install parts designed fr use in a CFC system. Use a charging statin. A/C charging statins and refrigerant recvery/recycling/charging statins minimize the release f CFCs and HFCs t the atmsphere. Use them fr all A/C charging and service wrk accrding t their manufactures instructins. D nt vercharge. This system requires nly the amunt f HFC-134a refrigerant shwn belw. If yu vercharge the system, the engine and the A/C wuld malfunctin. 500 t 550 grams.50 t.55 kilgrams 1.1 t 1.2 punds 17.6 t 19.4 unces INSTALLATION NOTE: Custmer Infrmatin: The infrmatin in these instructins is intended fr use nly by skilled technicians wh have the prper tls, equipment, and training t crrectly and safely add equipment t yur car. These prcedures shuld nt be attempted by d-it-yurselfers. Write dwn the custmer s radi statin presets; the radi memry will be erased when yu discnnect the battery. Make sure yu install the right part. Use the illustratins n pages 2 and 3 as a guide t check the parts befre yu install them. Dn t remve plugs and caps frm fittings until the parts are ready t cnnect. This will keep ut misture and dirt which culd cause wear and damage. Befre yu cnnect any line r hse, check and lube its O-ring. Make sure the O-ring is there (inside the fitting), put a few drps f refrigerant il n it and n the threads, then cnnect the fitting. Yu may use either type f refrigerant il t lubricate O-rings and fittings. If yu add r replace refrigerant il in the system, use nly this PAG il: ND il-8, P/N 38899-PR7- A01AH. Rute and secure the lines and hses prperly; maintain clearance between them and surrunding parts. Use tw wrenches t tighten r lsen fittings; hld ne fitting in place while yu tighten the ther ne against it. Befre yu cnnect each cnnectr, check its terminals. Make sure they aren t bent r ut f place. NOTICE Dn t vertighten; yu culd damage the fittings. Befre yu tighten a fitting, check the trque listed fr it. If leaks are caused by faulty O-rings, vertightening the fitting wn t help. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 1 f 20

Grup A 80560-SDA-A01 90127-SX0-003 (Gld) 80290-SDA-A01 80203-SDA-A01 79021-SDA-A01 80210-SDA-A01 Grup B 80411-SDA-A01 80412-SDA-A01 80271-SDA-A00 GROUP PART NAME PART NUMBER QUANTITY A A/C thermistr 80560-SDA-A01 1 A/C filter 80290-SDA-A01 1 A/C knb 80411-SDA-A01 1 A/C max knb 80412-SDA-A01 1 Drain hse 80271-SDA-A00 1 Evapratr 80210-SDA-A01 1 Evapratr lwer plate 80203-SDA-A01 1 Seal A 79021-SDA-A01 1 Self-tapping screw 90127-SX0-003 1 39794-SDA-A00 90023-PNA-000 (Yellw) 95701-10040-08 (Yellw) 90024-PNA-000 (Yellw) 38800-RAA-A01 80050-SR3-H00 38920-RAA-A02 38930-PNA-000 8005X-SDA-XXX GROUP PART NAME PART NUMBER QUANTITY B A/C infrmatin label 80050-SR3-H00 1 A/C kit label 8005X-SDA-XXX 1 Cmpressr 38800-RAA-A01 1 Cmpressr belt 38920-RAA-A02 1 Cmpressr bracket 38930-PNA-00 1 Flange blt 8x65mm 90024-PNA-000 2 (yellw) Flange blt 8x80mm 90023-PNA-000 2 (yellw) Flange blt 10x40mm 95701-10040-08 2 (yellw) Pwer relay 39794-SDA-A00 2 2 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

Grup C 80320-SDC-A01 91503-S7A-003 93403-06014-08 (Yellw) 93405-06030-05 (Gray) 38925-RAA-A00 90001-SDA-A00 (Yellw) 93403-06014-08 (Yellw) 93403-06014-08 (Yellw) 80362-SDA-A00 80100-SDA-A01 91548-SR3-003 80341-SDC-A01 80384-SM4-A01 93403-06016-08 (Yellw) 95701-06025-08 (Yellw) 80364-SDA-A00 94050-06080 (Yellw) 80315-SDA-A01 80311-SDA-A01 95701-06025-04 (Gray) GROUP PART NAME PART NUMBER QUANTITY A/C pipe clamp 80362-SDA-A00 1 A/C pipe unit 80320-SDC-A01 1 Clip 91503-S7A-003 2 Clip 8 mm 91548-SR3-003 1 Cndenser 80100-SDA-A01 1 Discharge hse 80315-SDA-A01 1 Flange blt 6x25mm 95701-06025-04 1 (gray) Flange blt 6x25mm 95701-06025-08 1 (yellw) Flange blt 6x38mm 90001-SDA-A00 1 (yellw) Flange nut 6mm (yellw) 94050-06080 2 Radiatr side seal 38925-RAA-A00 1 Receiver pipe 80341-SDC-A01 1 Receiver pipe clip 80384-SM4-A01 1 Suctin hse 80311-SDA-A01 1 Suctin pipe clamp 80364-SDA-A00 1 Washer-blt 6x16mm 93403-06016-08 1 (yellw) Washer-blt 6x14mm 93403-06014-08 3 (yellw) Washer-blt 6x30mm 93405-06030-05 2 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 3 f 20 C

1. Mve the wiper. Mve the wiper t the psitin shwn. Switch n the ignitin key. Switch ff the ignitin key with the wipers in the vertical psitin. 2. Remve the negative battery cable. NOTE: D nt allw the negative cable t make cntact with the psitive battery cable. Discnnect the negative terminal frm the battery. 4 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

3. Remve the right kick panel and the glve bx. Remve the glve bx. Pry the glve bx damper. *Take care nt t damage the damper hk. 2-clips Remve the side sill. Remve the tw washer blts. Reinstallatin trque: 5 N m (3.6 lb-ft) Frward Remve the right kick panel (tw clips). 4. Cut ut the dashbard frame. Remve the three cabin harness clips frm the dasbard frame. Remve this screw. Remve this screw. Cut ut the dashbard frame. *Be careful nt t damage the cabin harness r the blwer mtr. Attach prtective tape (duct tape) t the dashbard frame. Attach prtective tape (duct tape) t the dashbard frame. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 5 f 20

5. Discnnect the cnnectrs. Remve the thermistr sensr cnnectr frm the duct jint, then remve the cnnectr cap. Recirculatin cntrl cnnectr. Discnnect the vehicle harness cnnectr. Pry the harness clip. Pwer transistr cnnectr. Discnnect the vehicle harness cnnectr. Pry the harness clip. Remve the harness clamp. Frward Discnnect the vehicle harness cnnectr. 6. Remve the blwer unit. Remve the 6 mm paint cutting nuts. (Save.) Remve the 6x16 mm washer-blts. (Save.) Remve the 6x16 mm washer-blts. (Save.) Remve the 6 mm paint cutting nuts. (Save.) Remve the blwer unit. 6 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

7. Install the evapratr. Remve the blwer duct hle cver. Push the A/C hle plug tward the engine cmpartment, and discard it. 110 mm Remve seal A. (Discard.) Remve the blwer duct. (Save.) Install the new seal A. *D nt frget t install the seal A. Remve the evapratr dummy case, and discard it. Install the evapratr n the evapratr lwer plate, then insert the evapratr. Rute the evapratr line cnnectins thrugh the A/C hle in the dash. *Be careful nt t damage the evapratr cre. 8 screws 8. Install the A/C thermistr. Insert the A/C thermistr harness hk int the blwer duct. Remve and discard the sensr hle cver. Insert the A/C thermistr sensr int the sensr hle, and tighten the screw. 90127-SX0-003 (gld) Cnnect the A/C thermistr cnnectr, then snap the clip frm this cnnectr nt the blwer duct. Blwer duct 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 7 f 20

9. Install the drain hse. Drain nzzle Drain hse Vehicle harness Cabin side Drain hse Bdy panel White paint mark Drain hse Make sure that the edge f the drain hse reaches utside. Install the drain hse end f the drain nzzle. *Rute the drain hse under the vehicle harness. *Set with the white paint mark side facing dwn. *Make sure it has been crrectly installed. Remve and discard the drain nzzle cap. Remve and discard the drain hle plug. Raise the flr mat. Clip Remve the instrument center lwer cver. Remve the instrument center lwer cver. 5 Install the vehicle bdy drain hse grmmet int the drain hse. *Make sure it has been crrectly installed. *Make sure the drain hse prjects thrugh the bdy flr. Raise the flr mat. 10. Reinstall the blwer unit. Reinstall the 6 mm paint cutting nuts. (Reuse.) Reinstallatin trque: 9.8 N m (7.2 lb-ft) Reinstall the 6x16 mm washer blt. (Reuse.) Reinstallatin trque: 9.8 N m (7.2 lb-ft) Reinstall the 6 mm paint cutting nut. (Reuse.) Reinstallatin trque: 9.8 N m (7.2 lb-ft) Reinstall the 6x16 mm washer-blt. (Reuse.) Reinstallatin trque: 9.8 N m (7.2 lb-ft) Reinstall the blwer unit. Remve and discard the blwer plate. Install the dust and pllen filter. 8 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

11. Recnnect the cnnectrs. Recirculatin cntrl cnnectr Snap the harness clip nt the blwer unit. Recnnect the vehicle harness cnnectr. Pwer transistr cnnectr Recnnect the vehicle harness cnnectr. Snap the harness clip nt the blwer unit. Set the harness clamp. 12. Install the A/C switch knb. Frward Recnnect the vehicle harness cnnectrs. Remve the A/C switch cver. *Use a flat-tip screwdriver t carefully pry the cver ut. Install the A/C switch knb. Install the MAX A/C switch knb. Remve the MAX A/C switch cver. *Use a flat-tip screwdriver t carefully pry the cver ut. Apply prtective tape n the heater cntrl panel as shwn. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 9 f 20

13. Reinstall the remved cabin parts. Check if cmpleted. Remved parts 3 cabin harness cnnectrs Dashbard frame Glve bx [trque the munting blts t 5 N m (3.6 lb-ft)] Flr mat Right side lining cwl Instrument center lwer cver 10 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

14. Remve the grill cver and the air duct cver. Remve the grill cver. Frward Remve the intake air duct cver. Remve the air duct. 2-screws 8-clips 2-clips 15. Remve the strut bar and stay. Remve the 10 mm nuts. (Save.) Remve the engine hd weather strip. Remve the right side cwl tp, then slide the right side cwl tp as shwn. Remve the right side strut bar. (Save.) Remve the P/S hse clamp. (Save.) Remve the braket. (Save). Washer reservir Lift the P/S reservir frm its munting bracket and set it aside. CAUTION: D nt discnnect the hses f the reservir. Clips 10 mm nuts. Reinstallatin trque: 44 N m (32 lb-ft) Clip Washer-blts, 6 mm Reinstallatin trque: 9.8 N m (7.2 lb-ft) Washer-blts, 5 mm Reinstallatin trque: 5 N m (3.6 lb-ft) Remve the clip. (Save.) 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 11 f 20

16. Remve the alternatr belt. Turn the special tl in the directin f the arrw. Frward Remve the nut and the terminal. Discnnect the vehicle harness. Pry the harness clip. Set the special tl n the pulley center blt (hex blt) f the aut-tensiner. Remve the alternatr unit. (Save.) Remve and discard the alternatr belt. Remve the 10 mm munt blts. (Save.) 17. Install the cmpressr bracket and cmpressr. 95701-10048-08 10x40 mm (yellw) Tighten the tw 10x40 mm flange blts. Trque: 44 N m (32 lb-ft) Clean the areas where the cmpressr bracket blts will attach. Frward Set the cmpressr hks n the engine as shwn. Set the cmpressr bracket n the engine. Tighten all flange blts evenly. Trque: 22 N m (16 lb-ft) Install tw 8x80 mm (yellw) flange blts. (P/N 90023-PNA-000) Install tw 8x65 mm (yellw) flange blts. (P/N 90024-PNA-000) 12 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

18. Reinstall the alternatr. Frward Install the terminal and flange nut. Trque: 8 N m (5.9 lb-ft) 2 3 Plug in the cnnectr. 1 Snap the clip frm the alternatr wire harness. 4 Set the alternatr n the engine. 5 Tighten the flange blts (8x45 mm and 8x105 mm). Trque: 24 N m (17.7 lb-ft) 19. Install the cmpressr belt. Set the special tl n the pulley center blt (hex blt) f the aut-tensiner. Turn the special tl in the directin f the arrw. Frward Set the cmpressr belt n the pulleys. CAUTION: Check that the belt is prperly grved with the pulleys. Remve the special tl, and cnfirm whether the aut-tensiner is within the specified range using the indicatr. *If it is ut f specificatin, recheck the aut-tensiner referring t the service manual. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 13 f 20

20. Install the receiver pipe and the radiatr side seal. Remve the radiatr upper brackets. Set the receiver pipe int the receiver pipe clip. Install the receiver pipe clip nt the right side frame. Install the clips n the right side frame. Set the radiatr side seal n the radiatr side frame. 21. Install the cndenser and the discharge hse. Tighten the flange blts. Trque: 9.8 N m (7.2 lb-ft) 93405-06030-05 6x30 mm (gray) Install the discharge hse n the cndenser. Tighten the 6 mm flange nut. Trque: 9.8 N m (7.2 lb-ft) 94050-06080 6 mm (yellw) Tighten the flange blt. Trque: 9.8 N m (7.2 lb-ft) 95701-06024-04 6x25 mm (gray) Install the receiver pipe nt the cndenser. Reinstall the washer blts. Trque: 9.8 N m (7.2 lb-ft) Set back the radiatr. Install the radiatr upper bracket. Set the cndenser n the frnt lwer frame. *Be careful nt t damage the cndenser r radiatr cre. Reinstall the washer-blts. Trque: 9.8 N m (7.2 lb-ft) Install the radiatr upper bracket. 14 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

22. Cnnect the vehicle harness. Frward Frward Cnnect the cmpressr magnetic clutch cnnectr t the main vehicle harness cnnectr, then clamp the cnnectr n the fan shrud. Remve the magnetic clutch cnnectr frm the fan shrud, then remve and discard the cnnectr cap. Untape the main vehicle harness cnnectr. Remve and discard the cnnectr cap, then cnnect the main vehicle harness cnnectr t the cndenser pressure switch cnnectr. 23. Install the suctin hse and the discharge hse. (Cmpressr side) Remve and discard the suctin prt cap and blt f the cmpressr. Remve and discard the discharge prt cap and nut f the cmpressr. Tighten the flange nut. Trque: 9.8 N m (7.2 lb-ft) 94050-06080 6 mm (yellw) Cmpressr magnet clutch cable Install the discharge hse nt the cmpressr. *Rute the discharge hse under the cmpressr magnetic clutch harness. Tighten the flange blt. Trque: 9.8 N m (7.2 lb-ft) 95701-06025-08 6x25 mm (yellw) Install the suctin hse n the cmpressr. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 15 f 20

24. Install the A/C pipe unit. Tighten the washer. Trque: 9.8 N m (7.2 lb-ft) 93403-06014-08 6x14 mm (yellw) Cnnect the receiver pipe t the A/C pipe, and lsely tighten the flare nut f the receiver pipe. Cnnect the bracket f A/C pipe t the right side damper base. Damper base Tighten the flange blt. Trque: 9.8 N m (7.2 lb-ft) Lsely tighten the 6x38 mm flange blt. Receiver pipe 90001-SDA-A00 6x38 mm (yellw) Install the A/C pipe unit int the evapratr. Make sure that the A/C pipe is crrectly installed. 25. Install the bracket. Tighten the flare nut f receiver pipe. Trque: 13 N m (9.6 lb-ft) Tighten the washer blt. Trque: 9.8 N m (7.2 lb-ft) Install the bracket n the right side frame. Cnnect the receiver pipe t the clip. Reinstall the washer reservir, and snap the clip. Install the clip. 16 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

26. Tighten the suctin hse. 93403-06016-08 6x16 mm (yellw) Tighten the washer blt. Trque: 9.8 N m (7.2 lb-ft) A/C pipe unit Tighten the washer blt. Trque: 9.8 N m (7.2 lb-ft) 93403-06014-08 6x14 mm (yellw) 93403-06014-08 6x14 mm (yellw) Tighten the washer blt. Trque: 9.8 N m( 7.2 lb-ft) Clse the suctin pipe clamp. Attach the suctin pipe clamp t the bracket. Install the A/C pipe clamp t the right side frame. Install the suctin hse nt the A/C pipe, and lsely tighten the flare nut f the suctin hse. Bracket Tighten the flare nut f the suctin hse. Trque: 31 N m (22.8 lb-ft) 27. Install the pwer relays. Remve the lid f the fuse/relay bx. Install the tw pwer relays n the fuse/relay bx. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 17 f 20

28. Attach the A/C label. Attach the A/C infrmatin label n the damper base. Attach the A/C kit label n the engine hd between the SRS label and the hd prp hle. 18 f 20 8000X-S84-KC2KA AII 24039 (0209) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

29. Reinstall the remved engine rm parts. Check if cmpleted. Remved parts Grille cver Intake air duct cver/air duct Strut bar Right side cwl tp Engine hd weather strip P/S hse clamp P/S reserve tank Lid f the under-hd fuse/relay bx Negative battery cable 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24039 (0209) 8000X-S84-KC2KA 19 f 20