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Evaporator Core & Expansion Valve Replacement

WARNING: This page is about a different car, the 2011 Honda Insight and 2010 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.
  1. Recover the refrigerant with a recovery/recycling/charging station (see RECEIVER/DRYER DESICCANT REPLACEMENT ).
  2. Remove the cowl cover and the under-cowl panel (see COWL COVER REPLACEMENT ).
  3. Remove the bolts from the A/C line clamp (A).
    Fig 1: A/C Line Clamp, Bolts With Torque Specifications And O-Ring
    G06431381Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Remove the bolt, then disconnect the A/C line (B) from the evaporator core and remove the O-rings (C).
  5. Remove the blower unit (see BLOWER UNIT REMOVAL/INSTALLATION ).
  6. Remove the mode control motor (see MODE CONTROL MOTOR REPLACEMENT ).
  7. Disconnect the connectors (A) from the evaporator temperature sensor and the power transistor, then remove the connector clip (B). Remove the self-tapping screws, the expansion valve cover (C), and the seal.
    Fig 2: Identifying Expansion Valve Cover And Connector Clip
    G06431382Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Remove the self-tapping screw (A) and the cover (B).
    Fig 3: Identifying Self-Tapping Screw And Cover
    G06431383Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Remove the bolts and the expansion valve from the evaporator core assembly without bending the lines.
    Fig 4: Identifying Expansion Valve
    G06431384Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Carefully pull out the evaporator core assembly (A), then remove the plate (B).
    Fig 5: Identifying Evaporator Core Assembly And Plate
    G06431385Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Pull out the evaporator temperature sensor (A) from the evaporator core.
    Fig 6: Identifying Evaporator Temperature Sensor
    G06431386Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Install the evaporator temperature sensor in the evaporator core, and note these items:
    • When the evaporator temperature sensor (A) is installed into the new evaporator core, set the sensor into the factory-preset position (B, C).
    • When the evaporator temperature sensor is reinstalled into the original evaporator core, set the sensor into the new position (D, E) because the fin may be deformed by the previous installation.

    Installing into the factory-preset position 

    Fig 7: Installing Into Factory-Preset Position
    G06431387Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Installing into the new position 

    Fig 8: Installing Into Position
    G06431388Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install the core in the reverse order of removal and note these items:
    • If you're installing a new evaporator core, add refrigerant oil (SP-10) (see A/C SERVICE TIPS AND PRECAUTIONS ).
    • 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 (see SYSTEM CHARGING ).
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