Presentation on theme: "1994 Accord A/C Rebuild This slide show will walk you through the steps required to repair the air conditioning system in a 1994 Honda Accord after a compressor."— Presentation transcript:
1994 Accord A/C Rebuild This slide show will walk you through the steps required to repair the air conditioning system in a 1994 Honda Accord after a compressor failure. No part of this presentation can be used for financial gain or personal distribution.
1994 Accord A/C Rebuild When a compressor fails it typically releases contaminants into the system. These can cause other parts to fail and poor A/C system performance. All parts must be removed and either replaced or cleaned. There are NO short cuts.
1994 Accord A/C Repair Many shops will want close to $2,000 to do this repair, but you can do it yourself with the right parts, tools, and some time. I did my system for $900 which included taking the car to the shop to have the system evacuated, and returning after my work was completed to have it vacume tested and recharged. Those trips cost me $100 each.
1994 Accord A/C Repair You will need to buy the following parts. New or Remanufactured Compressor, Dryer, All O Rings, Compressor Manifold Gasket, Condensor, and 8 Oz of PAG- 150 oil. You will also need a few large cans of brake cleaner non-residue type, upper and lower radiator hoses, Anti- Freeze and an air compressor. Its also helpful to have several large sets of wrenches and/or adjustables to break the lines. Also have handy some cheap sandwich bags and rubber bands.
1994 Accord A/C Repair OK, the first thing you want to do is take a few digital shots of the engine compartment before you touch a thing. This way you can go back and reference the way things were during reassembly if you get stuck. Somewhere under there is where the lines connect to the Evaporator.
1994 Accord A/C Repair This is the battery area. Under the battery and its tray and that little white over flow canister is the dryer. All of this must come out to get to those parts and the lines. Note the positioning of the charging ports. (Blue caps.)
1994 Accord A/C Repair This is another angle of that same crowded area. The radiator hoses are original to the car and will be replaced during this process while its easy to do.
1994 Accord A/C Repair Another shot of the crowded left rear area near where the lines connect to the Evaporator.
1994 Accord A/C Repair This shot shows the radiator, fans, and low pressure line. The compressor is in there too under all of that “stuff”.
1994 Accord A/C Repair Here is a closer shot showing the location of the compressor just below the alternator (With the black boot on the back). Everything in the foreground except the exhaust manifold must be removed to get it out.
1994 Accord A/C Repair This is the area around the compressor. Its well buried under there. You can see the power steering pump and the high and low pressure lines.
1994 Accord A/C Repair This shot shows the radiator and fans as well as the high and low pressure lines etc.
1994 Accord A/C Repair As mentioned before, the dryer is located under the battery and battery tray. You can see it by removing the radiator overflow canister.
1994 Accord A/C Repair Now that we have a good idea where everything is located, lets begin the repair. Remove the battery and battery tray and set aside in a safe place out of your way.
1994 Accord A/C Repair Also remove the air intake snorkel, and that black charcoal canister so you can get to those lines.
1994 Accord A/C Repair Drain the radiator. Then, remove the upper radiator hose, cut the bottom hose and remove the upper half and toss both out. If you have an automatic, disconnect the cooling lines at the front of the motor. Remove the two upper brackets to free the radiator. Carefully lift the radiator and fan assembly out as one unit. Remove the toss out the lower half of the old lower radiator hose. We can see the compressor better now.
1994 Accord A/C Repair Remove the grille and set aside. This gives you access to the front of the Condensor and the two high pressure line connections.
1994 Accord A/C Repair You will see a connection like this on each side of the front of the Condensor. Carefully remove the bolts and pull the hose from the connection. This is an O Ring sealed connection.
1994 Accord A/C Repair Lift the Condensor out of the car. Next remove the lines from the compressor. Carefully undo the retaining nut and lift the hose off. Disconnect the lines from the Dryer, remove and discard the Dryer. Last, using two wrenches, remove the first half of the low pressure line located in front of the motor, then remove the rest of the lines from the Evaporator. This leaves only the Compressor left to remove. As you remove the lines, place a sandwich bag over the end and secure with a rubber band. This helps prevent moisture from getting into the lines.
1994 Accord A/C Repair Take all of your lines to a clean work area and have a few clean cotton cloths handy. Spray a ton of brake cleaner into a pipe. Then blow it out using compressed air. Wipe the outside of each line with a clean cloth. Inspect each for heavy oily deposits, these are signs of leaks. If you detect a leak in a line or see cracks, you must replace the line. Once a line is clean, put clean sandwich bags over the ends and secure with rubber bands.
1994 Accord A/C Repair Here I am blowing out one of the smaller lines with compressed air. Take your time and make sure you get all residue out of the lines. They should blow out clean, not gray or black. Repeat until they blow out clean break cleaner.
1994 Accord A/C Repair You will use about 3 large cans of brake cleaner to do the job. More if your going to take the chance of using the old Condensor. They are cheap enough, and it was more of a pain to clean it than replace it, so I just installed a new one.
1994 Accord A/C Repair Careful not to get any of that brake cleaner in your face! Its nasty. You will hear about an orifice valve on some forums. This car does not have one so don’t worry about it. That part of the operation is taken care of by a valve in the Evaporator.
1994 Accord A/C Repair Here is one of the longer lines getting a good cleaning. This is a high pressure line and holds he high pressure switch.
1994 Accord A/C Repair The Dryer caught most of the junk the seizing Compressor sent into the system. That is its job and my failure was not severe. This line is after the Dryer and was pretty clean. This was good as it meant that I would probably not have to worry about the Evaporator.
1994 Accord A/C Repair Moving along nicely now. Here is one of the larger low pressure lines being cleaned.
1994 Accord A/C Repair After your done cleaning all of the lines. Gently remove the old O Rings as shown here and replace with genuine Honda replacements. Put a small daub of PAG oil on them after they are installed.
1994 Accord A/C Repair Replacing more O Rings. Always replace ALL O Rings and the Compressor manifold gasket. Never re-use them as your just asking for trouble with leaks.
1994 Accord A/C Repair The dirt and debris from the compressor failure did not reach our Evaporator thankfully. I sprayed some brake cleaner into those line holes and blew them out as best as I could. It will only blow out in one direction so do not be alarmed. If you flushed a good bit of debris from your high pressure line that goes from the Dryer to this connection, then you may have to remove the Evaporator for cleaning. This requires disassembly of the interior of the car on the passenger side to remove the Evaporator box. A big job…
1994 Accord A/C Repair Next we remove the old compressor. Ours had seized up and when the clutch was engaged it spun and cooked the clutch innards which melted and sprayed all over the place. This was probably better than having it burn up the belt and strand the wife.
1994 Accord A/C Repair Carefully remove the Compressor manifold. We can see that our compressor is black inside which is not good as that is a sign of high heat and ground up metal. Carefully cut the clutch leads and connector off about 2 inches back from the connector. Clean this connector up with contact cleaner, and use the brake cleaner to clean the manifold.
1994 Accord A/C Repair Here is our remanufactured Compressor, and our cleaned up manifold. I had to use a small moto-tool with a wire brush to get the manifold cleaned up.
1994 Accord A/C Repair Remove the shipping plate from the new Compressor. Drain all oil if any from the unit. Replace the manifold gasket with a new one from Honda. Slowly pour about 6 Oz of PAG-150 oil into the compressor and slowly turn the clutch to work it around. Install the manifold on the Compressor. Using automotive wire splicers, splice your old clutch connector onto the clutch leads making the overall length of the connector leads the same as the originals.
1994 Accord A/C Repair Install your new compressor on the car. Tension the belt according to usual methods for your car and secure the alternator bolt.
1994 Accord A/C Repair This is our new Condensor. With a Compressor failure and given the age of the car (11 years old), it’s a good thing to replace this part now.
1994 Accord A/C Repair Drop your Condensor into place. Make sure you’ve got it oriented correctly.
1994 Accord A/C Repair Install the short high pressure line to the left front side of the Condensor. The other end of this line connects to the Dryer. Remember to have a small daub of PAG oil on the O-Ring before you install the line to prevent damage to the O-Ring and help make a good seal.
1994 Accord A/C Repair Next I installed a new lower radiator hose to the radiator and clamped it tight. I then lowered the entire radiator and fan assembly into the car. Secure the other end of the lower radiator hose to its port. Replace the radiator support brackets.
1994 Accord A/C Repair Next install the other high pressure line that goes to the compressor. Again, remember to put a daub of PAG oil on the O ring. This line ended up having an age crack in it and needed to be replaced a few weeks after I finished the job costing me an extra $229. Really inspect those hoses and lines well before cleaning and reinstallation.
1994 Accord A/C Repair Here is another shot of the progress just after installing the radiator. Also do not forget to hook up the transmission fluid cooling lines at this time if you have an automatic.
1994 Accord A/C Repair Put about 1 Oz of PAG- 150 oil into the Dryer. Then install the new Dryer connecting its short line from the Condensor. Snug up all threaded connections as you go but do not over tighten as you can easily strip threads and that’s a costly mistake as the part must be replaced, and Honda parts are not cheap.
1994 Accord A/C Repair Secure the other end of the high pressure line from the Condensor to the compressor manifold.
1994 Accord A/C Repair Place about 1 Oz of PAG- 150 oil into the low pressure line. Then install the two segments of the low pressure line and its bracket. Make sure to use two wrenches on the couplings so you do not stress any of the lines and connections.
1994 Accord A/C Repair This is your connection point for the low pressure line to the Evaporator. Snug this up carefully as its easy to crack the Evaporator and this would cost you a ton of work not to mention some bucks for a replacement.
1994 Accord A/C Repair Next install the high pressure line between the Dryer and Evaporator. This is the connection at the Evaporator. Use two wrenches here.
1994 Accord A/C Repair Here is the connection at the Dryer end. Note how the two charging ports (with blue caps) are aligned and both generally pointing towards the motor as was the original alignment. Once into position, snug all connections up.
1994 Accord A/C Repair Replace the charcoal canister and your air cleaner and its snorkle making sure you reconnect and tighten anything you may have moved or loosened to give yourself clearance back in this area.
1994 Accord A/C Repair Replace your battery tray and upper radiator hose. Refill the radiator with fresh Anti-Freeze and a little water.
1994 Accord A/C Repair We’re almost done now, all we need to do is double check our work, recheck all connections, make sure we did not forget to reinstall anything.
1994 Accord A/C Repair OK, reinstall your battery and tie down and connect the cables. At this time we are done. If you have the ability to vacume test and charge the system, you can do so. At this point the Compressor will not kick on if we tried to use the A/C as the pressure switch would not detect any coolant. I took the car to a certified shop and had them do a 30 minute vacume test which it passed, then they charged the system. Make sure you tell them you’ve already put 8 Oz of PAG- 150 oil in the compressor and lines.
1994 Accord A/C Repair This concludes our presentation. Hopefully you found this helpful, and it gave you enough information to determine if you can do a job of this magnitude. I saved about $900 by doing the job myself. After charging at the shop the A/C ran smooth and quiet, and blew nice cool air. She still runs perfectly to this day nearly two years later.