INSTALLATION INSTRUCTIONS - PDF Free Download

INSTALLATION INSTRUCTIONS Accessry Applicatin Publicatins N. All 24107 AIR CONDITIONER ELEMENT (DX) Issue Date DEC 2002 What s New INSTALLATION The A/C kit and instructins fr the 2003 Element 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 Aut-tensiner wrench 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 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 17.6 t 19.4 unces 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 24107 (0212) 1 f 20

PARTS LIST KIT N.80000-SCV-A50 COMPRESSOR 38800-PZD-A01 1 COMPRESSOR BRACKET 38930-PNA-000 1 COMPRESSOR BELT 38920-PZD-A01 38920-PZD-A00 1 CONDENSER FAN 38605-PZD-A01 1 CONDENSER 80100-SCV-A01 1 LEFT UPPER CONDENSER BRACKET 80111-S9A-000 1 RIGHT UPPER CONDENSER BRACKET 80112-S9A-000 1 SUCTION HOSE 80311-SCV-A01 1 SUCTION PIPE HOSE CLAMPA 80361-SK7-010 1 SUCTION PIPE CLAMP 80364-SF1-000 2 DISCHARGE HOSE 80315-SCV-A11 80315-SCV-A01 1 A/C PIPE UNIT 80320-SCV-A01 1 RECEIVER PIPE A 80341-SCV-A01 1 RECEIVER PIPE B 80342-SCV-A02 80342-SCV-A01 1 RECEIVER PIPE CLIP B 80384-SM4-A01 2 CLIP 8mm 91548-SR3-003 2 EVAPORATOR 80210-S5D-G03 1 EVAPORATOR SENSOR 80560-S5A-941 1 DRAIN HOSE 80271-S9A-000 1 DRAIN HOSE CLIP 91597-S5H-T31 1 POWER RELAY 39794-S0K-A10 39794-S0K-A01 2 A/C INFORMATION LABEL 80050-SR3-H00 1 A/C KIT LABEL 8005X-SCV-A50 800XX-XXX-XXX 1 A/C KNOB 79601-SCV-A01 1 TURN DIAL COMP 79604-SCV-A01 1 A/C MODE DISPLAY 79606-SCV-A01 1 WASHER BOLT 6x16mm (GRAY) 93403-06016-05 2 WASHER BOLT 6x12mm (YELLOW) 93403-06012-08 3 WASHER BOLT 6x16mm (YELLOW) 93403-06016-08 2 FLANGE BOLT 6x25mm (YELLOW) 95701-06025-08 2 FLANGE BOLT 6x30mm (YELLOW) 95701-06030-08 1 FLANGE BOLT 10x40mm (YELLOW) 95701-10040-08 2 FLANGE BOLT 8x65mm (YELLOW) 90024-PNA-000 2 FLANGE BOLT 8x80mm (YELLOW) 90023-PNA-000 2 FLANGE NUT 6mm (YELLOW) 94050-06080 2 PAINT CUTTING NUT 6mm (YELLOW) 90361-SV4-003 2 4 f 20 AII 24107 (0212) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

1. Remve the negative battery cable. NOTE: D nt allw the negative cable t make cntact with the psitive cable. Discnnect the negative terminal frm the battery. 2. Remve the passenger s dashbard under cver and glve bx. Remve the tw washer blts and remve the the glve bx. Reinstallatin trque: 5 N m (3.6 lb-ft) Remve the passenger s kick panel. (2 clips) Remve the passenger s dashbard under cver. (3 clips) Frward 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24107 (0212) 5 f 20

3. Cut ut the dashbard frame and remve the glve bx frame. Remve the tw relay sckets and the harness clip. Attach prtective tape (duct tape) t the dashbard frame and blwer unit. D nt damage the cabin harness r blwer unit. Reinstallatin trque: 5 N m (3.6 lb-ft) Remve and discard frame. Remve the glve bx frame. Cut ut the dashbard frame as shwn. 4. Remve the ECM/PCM and discnnect the cnnectrs. Remve the ECM/PCM and the ECM/PCM bracket. (three washer blts) (tw flange nuts) Reinstallatin trque: Discnnect the three ECM/PCM cnnectrs and the 20-pin harness cnnectr. Pry t remve. Discnnect. Recirculatin cntrl mtr cnnectr Discnnect. Pwer transistr cnnectr Blwer mtr cnnectr Pry t remve. Discnnect. Pry t remve. 6 f 20 AII 24107 (0212) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

5. Remve the blwer unit. Remve blts. Remve blwer unit while pulling dwn n frame. Remve nut. 6. Install the evapratr. Remve blt. Remve nut. Reinstallatin trque: Remve the heater plate and discard. Push the A/C hle plug tward the engine cmpartment. Remve and discard plug. Remve the expansin valve cver. (six screws) Install the expansin valve cver. (six screws) Install the evapratr int the heater unit. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24107 (0212) 7 f 20

7. Install the evapratr sensr. Remve the driver s dashbard lwer cver. Plug in cnnectr. Heater case Install evapratr sensr and turn clckwise until it clicks. Heater case Blue tape Remve and discard cver. 8. Reinstall the blwer unit. Attach cnnectr. Untape sensr cnnectr frm the harness. Reinstall blts. Reinstallatin trque: Reinstall blwer unit. Reinstall nut. Reinstallatin trque: Reinstall blt. Reinstallatin trque: Reinstall nut. Reinstallatin trque: 8 f 20 AII 24107 (0212) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

9. Reinstall the ECM/PCM unit and the cnnectrs. Reinstall the ECM/PCM bracket and the ECM/PCM. (three washer blts and tw flange nuts) Reinstallatin trque: Cnnect the three ECM/PCM cnnectrs and the 20-pin harness cnnectr. Reattach. Recnnect. Recirculatin cntrl mtr cnnectr Recnnect. Pwer transistr cnnectr Reattach. 10. Install the A/C switch knb and the A/C mde display. Reattach. Blwer mtr cnnectr Recnnect. Reattach. Reinstall the temperature cntrl dial. Reinstall the mde cntrl dial. Turn the temperature cntrl dial t MAX COOL, and remve temperature cntrl dial. Install the new A/C switch knb. Turn the mde cntrl dial t VENT, and remve the dial. Remve the A/C switch lid, and discard the lid. Install the new mde cntrl display. Apply prtective tape as shwn. (masking tape) Remve the mde cntrl display, and discard. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24107 (0212) 9 f 20

11. Install the drain hse. Heat shield Remve the fur flange blts, and remve the heat shield. Reinstall the heat shield with fur flange blts. Reinstallatin trque: Install drain hse and psitin white paint mark facing up. Paint mark Install clip. Remve and discard drain nzzle cap. 12. Reinstall the remved cabin parts. Check if cmpleted. Remved parts Passenger s dashbard under cver Glve bx Passenger s kick panel Right side kick panel Glve bx frame Relay sckets and harness clip Driver s dashbard lwer cver. 10 f 20 AII 24107 (0212) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

13. Remve the frnt bumper. Remve blulkhead cver. (five clips) Remve the splashshield. (ten clips) Frnt bumper Remve the frnt bumper. (thirteen clips, fur washer blts, and tw screws) 14. Remve the bulkhead and upper radiatr bracket. Discnnect reservir hse, and remve the reservir. Remve reservir blt. Remve the upper radiatr bracket. Remve washer blts. Reinstallatin trque: Remve washer blts. Remve the upper radiatr bracket. Remve washer blts. Reinstallatin trque: Remve bulkhead. Remve washer blts. Reinstallatin trque: 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24107 (0212) 11 f 20

15. Remve the alternatr belt. Apply pressure t the tl in this directin t lsen belt. Install tl Remve and discard belt. 16. Remve the pwer steering pump and altermatr. Lift the pwer steering reservir frm its munt and psitin a side. Lift the pwer steering pump frm its munt and psitin a side. DO NOT discnnect the pwer steering hses. Reinstallatin trque: 8 N m (6 lb-ft) Remve the nut and terminal. Discnnect. Pry harness clip. Remve tw blts. (M8x45mm) Reinstallatin trque: 24 N m (18 lb-ft) Remve the alternatr. Remve three blts. (2-M8x45mm) (1-M8x105mm) Reinstallatin trque: 24 N m (18 lb-ft) 12 f 20 AII 24107 (0212) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

17. Install the cmpressr bracket and cmpressr. Install the tw new flange blts. Installatin trque: 44 N m (32 lb-ft) Psitin the tw cmpressr hks as shwn. Clean the area where the cmpressr bracket will attach. Install the cmpressr bracket. Install the tw new flange blts and tighten. Installatin trque: 22 N m (16 lb-ft) Install the tw new flange blts lsely. Tighten blts. Installatin trque: 22 N m (16 lb-ft) 18. Install the suctin hse and the discharge hse (cmpressr side). Rute the discharge hse under the right side headlight. Remve and discard the nut and cap. Discharge hse Remve and discard the nut and cap. Install suctin hse and new nut. Installatin trque: Install discharge hse and new nut. Installatin trque: Discharge hse Discharge hse 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24107 (0212) 13 f 20

19. Reinstall the alternatr. Reinstallatin trque: 8 N m (6 lb-ft) Reinstall terminal and nut. Recnnect. Attach clip. Reinstall P/S pump. Reinstall tw blts. (M8x45mm) Reinstallatin trque: 24 N m (18 lb-ft) 20. Install the cmpressr belt. Reinstall the alternatr. Reinstall three blts. (2-M8x45mm) (1-M8x105mm) Reinstallatin trque: 24 N m (18 lb-ft) Apply pressure t the tl in this directin t lsen tensiner. Install tl Belt ruting Install the new belt and rute as shwn. Remve tl and cnfirm if the aut-tensiner is within specificatins using the indicatr. 14 f 20 AII 24107 (0212) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

21. Install the cndenser fan. Recnnect reservir hse. 93403-06016-05 6x16mm Gray Install the cndenser fan n the radiatr, and tighten the tw new washer blts. Reinstallatin trque: Reinstall the reservir and psitin the tab as shwn. Reinstall the blt. Reinstallatin trque: Tab Pull the tp f the radiatr utward. 22. Install the cndenser. Install the suctin pipe clamp A and new blt. Installatin trque: 9.8 N m (7.2 lb-ft) Psitin the right cndenser bracket. Installatin trque: Install the discharge hse and new blt t the cndenser. Installatin trque: 9.8 N m (7.2 lb-ft) Psitin the cndenser n the frnt lwer frame. Install the receiver pipe B t the cndenser, and tighten the new flange blt. Reinstallatin trque: Psitin the left bracket n the cndenser and install new blt. Installatin trque: L and R are indicated n brackets. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24107 (0212) 15 f 20

23. Cnnect the vehicle harness. Blue tape Cnnect the cndenser fan mtr cnnectr t the vehicle harness. Untape (blue tape) the cndenser fan mtr cnnectr. Remve and discard the prtective cap. Untape (blue tape) the cmpressr magnetic clutch cnnectr. Cnnect the cmpressr clutch cnnectr t the vehicle harness, and attach the cnnectr t the fan shrud. Remve and discard the prtective cap. Attach the harness clip t the fan shrud. 24. Reinstall the bulkhead and upper radiatr bracket. Reinstall the upper radiatr brackets. Install tw blts. Installatin trque: Install tw blts. Installatin trque: Reinstall the bulkhead. Install tw blts. Installatin trque: Install tw blts. Installatin trque: 16 f 20 AII 24107 (0212) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

25. Install the A/C pipe unit. Install new paint cutting nuts. Installatin trque: 9.8 N m (7.2 lb-ft) Remve the flange blt, bracket, and discnnect the harness clip. Install the A/C pipe unit with new blt t the evapratr. Installatin trque: Attach clip. Attach pipe. Install the suctin pipe clamp and new blt. Installatin trque: 26. Install the receiver pipe A. Install receiver pipe A and tighten lsely. Tighten flare nut. Installatin trque: 13 N m (9.5 lb-ft) Install receiver pipe A and tighten lsely. Attach clip and pipe. Attach clip and pipe. Untape (blue tape) the pressure switch cnnectr, remve the prtectice cap frm the pressure switch, and cnnect the harness t the pressure switch. Attach clip and pipe. 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24107 (0212) 17 f 20

27. Tighten the suctin hse. Attach the suctin pipe clamp and tighten the new washer blt. Installatin trque: A/C pipe unit A/C pipe unit Tighten flare nut. Installatin trque: 31 N m (23 lb-ft) Attach suctin hse. A/C pipe unit 28. Install the pwer relay. Remve the underhd fuse/relay bx lid. Install the tw pwer relays. 18 f 20 AII 24107 (0212) 2002 American Hnda Mtr C., Inc - All Rights Reserved.

29. Attach the A/C label. Attach the A/C infrmatin label n the center f the hd. Attach the A/C kit label n the left side f the hd. 30. Reinstall the remved engine rm parts. Check if cmpleted. Remved parts Bulkhead cver Frnt bumper Splash shield Pwer steering reservir Bracket Main vehicle harness clamp Lid f the under-hd fuse/relay bx Negative battery cable Reset the custmer s radi statins 2002 American Hnda Mtr C., Inc - All Rights Reserved. AII 24107 (0212) 19 f 20