1

Receiver & Dehydrator

85716259

1

Heater & Blower Module Bolt

11603972

2

BEV POI Oil Type PZ

38899-REV-A01

1

REQUIRED MATERIALS
Part Name

Part Number

Quantity

Electrical Contact Cleaner

Commercially Available

1

Tool Name

Tool Number

Quantity

Mahle A/C Machine

RTIACX2282

1

A/C Oil Injector

07-J-45037

1

R1234yf A/C Oil Injector Hose

07-GE-50745

1

TOOL INFORMATION

Page 4 of 18

INSPECTION / REPAIR PROCEDURE
1. Disconnect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
2. Raise the vehicle. See Lifting and Jacking the Vehicle.
3. Remove the underbody rear air rear deflector. Do steps 2–6 of the Removal Procedure in Underbody Rear Air Rear
Deflector – Rear.
4. Locate the body wiring harness to chassis harness connector at the right-rear underside of the vehicle and remove it
from the bracket for access.

Page 5 of 18

5. Inspect the back side of the chassis harness connector. The following cavity locations should have either a wire or
cavity plug inserted (depending on the vehicle trim).

5.1 For the large and medium sized cavities that do not have wire terminals inserted, check that the gray or red cavity
plugs are in place and fully seated. A fully seated cavity plug will sit below the body of the connector.

Page 6 of 18

5.2 Inspect the large and medium cavity plugs for missing or fully unseated (all 3 ribs are visible) plugs.
Examples of missing or fully unseated cavity plugs:
Missing Plugs

Unseated Plugs

Correct

Are any cavity plugs missing or fully unseated with all 3 ribs visible?
YES – Proceed to step 6.
NO – Proceed to step 8.
NOTE: If the cavity plugs are in place but sitting above the connector (not fully seated), use a flat screwdriver and
push the cavity plug in until it is fully seated and sitting below the connector.

Page 7 of 18

6. Since cavity plugs are missing or fully unseated, the connector terminals need to be Inspected for corrosion.
6.1 Slide the release lock to unlock the connector.

6.2 Press the release tab on the corner of the connector (1) to release the lock, then slide the outer case in the direction
shown (2) to release the connector.

Page 8 of 18

6.3 Inspect both connectors for corrosion on the connector terminals.

Is corrosion present on the connector terminals?
YES – Use electrical contact cleaner to remove the surface corrosion, then go to step 6.4.

Do not use brake or fuel system cleaners as they can damage the connectors.
NOTE: Corrosion on the body harness connector is not expected.
NO – Proceed to REPAIR PROCEDURE – Missing Cavity Plugs.
6.4 Was the corrosion successfully removed?
YES – Go to step 7.
NO – Take detailed photos clearly showing presence of corrosion on one or both of the connectors. Then, go to
PARTS INFORMATION to submit a request for the chassis harness, body harness, or both. Once the
harness(es) request is approved and shipped, go to the BODY / CHASSIS HARNESS REPLACEMENT
instructions.
7. Reconnect the chassis and body harness connectors.
8. Reattach the harness connectors to the mounting bracket.
9. Install the underbody rear air rear deflector – rear. Do steps 1–5 of the Installation Procedure in Underbody Rear Air
Rear Deflector – Rear.
10. Lower the vehicle.
11. Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
12. Clear all DTCs.

Page 9 of 18

REPAIR PROCEDURE

Missing Cavity Plugs
1. If any cavity plugs are missing from the connector body (A), use the appropriately sized cavity plug, large (gray) or
medium (red), and insert it into the empty cavity of the connector body. Use a small flat screwdriver to insert the cavity
plug fully into the connector body (B). Ensure the cavity plug is fully seated into the cavity and sitting below the
connector body (C).

2. Reconnect the harness connectors and attach the harness connectors to their mounting bracket.
3. Reinstall the underbody rear air rear deflector - rear. Do steps 1–5 of the Installation Procedure in Underbody Rear Air
Rear Deflector – Rear.
4. Lower the vehicle.
5. Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
6. Clear all DTCs.

Page 10 of 18

BODY / CHASSIS HARNESS REPLACEMENT
IMPORTANT: Complete the repair by following all designated steps in the referenced hyperlinks.
Replace the Chassis Harness
NOTE: Only replace the chassis harness if the corrosion on the chassis harness terminals cannot be removed with the
electrical contact cleaner.
1. Before replacing the chassis harness, take clear photos of the corrosion on the chassis harness connector. These
photos must be submitted with the warranty claim.
2. Remove the automatic forward lighting leveling position sensor connectors (1), then remove the rear wheel speed
sensor connectors (2). Unclip the harness retainers (3, 4).

3. Install the new chassis harness in the reverse order of removal. Make sure the mounting clips are properly secured, and
the connectors have all been reattached.
4. Reinstall the underbody rear air rear deflector - rear. Do steps 1–5 of the Installation Procedure in Underbody Rear Air
Rear Deflector – Rear.
5. Lower the vehicle.
6. Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
7. Clear all DTCs.

Page 11 of 18

Replace the Body Harness
NOTE:
• Only replace the body harness if the corrosion on the body harness terminals cannot be removed with the electrical
cleaner.
• Refer to PARTS INFORMATION for a list of parts that must be replaced during the body harness replacement.

•
•

Interior trim panels are attached to the body structure using metal clips. Pulling on the panel can result in damaged
parts.
To reduce the risk of damaging the mounting clips or the panels, use a suitable trim/clip removal tool to release the clip
from the body structure.
Panel Removal Tip:
1. Slide the trim/clip tool between where the
trim panel is secured to the body structure.

2. Gently twist the trim/clip tool to release
the metal clip from the body structure.

TIP: Make sure Techline Connect is up to date before proceeding with this repair.
1. Before replacing the body harness, take clear photos of the corrosion on the body harness connector. These photos
must be submitted with the warranty claim.
2. Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.

Page 12 of 18

3. Recover the refrigerant.
3.1 Launch the Techline Connect service diagnostic tool to open the system valves. Select the K16 Battery Energy
control module scan tool function.
3.2 Select GDS2.

3.3 Select Module Diagnostics.

Page 13 of 18

3.4 Select Battery Energy Control Module.

3.5 Select Control Functions.

3.6 Select Air Conditioning Refrigerant Evacuation and Service Fill Request.

Page 14 of 18

3.7 Select Start.

3.8 Once the valves are open, start recovering the refrigerant.

3.9 Recover the refrigerant using the Mahle machine only, (T/N RTIACX2282). For more information refer to
Refrigerant Recovery and Recharging.
NOTE:
• Do not use the Robinair Machine, it will not output the correct information for recovered POE oil.
• Record the exact amount of refrigerant oil recovered from the vehicle as the same amount of oil recovered will
be needed to recharge the system. Rever to Job Aid ZDX A/C Diagnosis and Leak Check.
4. Confirm all doors are unlocked.
5. Open the tailgate.
6. Unbolt the front seats, step 2 only in Front Seat Removal and Installation.
NOTE: Do not disconnect the power seat harness connectors at this time.
7. Disable the SIR system. See SIR Disabling and Enabling.
8. Disable the High Voltage system. See High Voltage Disabling.
9. Remove the left side front floor panel carpet. See Front Floor Panel Carpet Replacement – Left Side.
10. Remove the right side front floor panel carpet. See Front Floor Panel Carpet Replacement – Right Side.
11. Remove the rear floor panel carpet. See Rear Floor Panel Carpet Replacement.
12. Remove the left quarter lower rear trim panel. See Quarter Lower Rear Trim Panel Replacement – Left Side.
13. Remove the right quarter lower rear trim panel. See Quarter Lower Rear Trim Panel Replacement – Right Side.
Page 15 of 18

14. Remove the headliner. See Headlining Trim Panel Replacement.
15. Remove the turn signal switch. See Turn Signal Switch Replacement.

During the removal of the turn signal switch, there are two spring tabs securing the turn signal switch to the steering
column. Gently pry the spring tabs until the turn signal switch releases from the steering column with light pressure.
Excessive pressure can break the spring tabs. If the tabs break the turn signal switch must be replaced.

16. Disconnect the refrigerant lines from the evaporator and remove the evaporator and blower module mounting bolts, do
steps 6 – 9 in Heater and Air Conditioning Evaporator and Blower Module Removal and Installation.
17. Remove the instrument panel See Instrument Panel Removal and Installation.
17.1 Do steps 3 – 26.
NOTE: Do not do steps 27-28, seats should already be removed.
17.2 Do steps 29 – 66.
NOTE: Do not do steps 67-78, instrument panel will be removed as an assembly.
17.3 Do steps 79 – 98.
NOTE: Do not do step 99, instrument panel will be removed as an assembly.
17.4 Do steps 100 – 113.

Page 16 of 18

17.5 With the aid of an assistant, lift the instrument panel assembly up and rearward to release the assembly off the
locating pins, then remove it from the vehicle.

18. Remove the front underbody rear air rear deflector. See Underbody Rear Air Rear Deflector Replacement – Front.
19. Remove the middle underbody rear air rear deflector. See Underbody Rear Air Rear Deflector Replacement – Middle.
20. Remove the rear underbody rear air rear deflector. See Underbody Rear Air Rear Deflector Replacement – Rear.
21. Remove the stop lamp assemblies. See Rear Body Structure Stop Lamp Replacement.
22. Remove the headlamp assemblies. See Front Headlamp Replacement.
23. Remove the radiator upper air baffle and front bumper energy absorber, do steps 5 – 8 in Front Bumper Shutter
Replacement.
24. Remove the battery tray. See Battery Tray Replacement.
25. Remove the body wiring harness. Use Harness Routing Views as a reference.
TIPS:
•

Before removing the wiring harness, take photos to use as a reference during the new wiring harness installation.

•

Marking the old harness before removal can help as a reference with proper harness location during assembly.

26. Install the new body wiring harness.
27. Replace the receiver dehydrator,
• All Wheel Drive: See Air Conditioning Receiver and Dehydrator Replacement.
• Rear Wheel Drive: See Air Conditioning Receiver and Dehydrator Replacement
28. Reinstall the remaining parts in the reverse order of removal.

Page 17 of 18

29. Connect the 12-volt battery. See Battery Negative Cable Disconnection and Connection.
30. Recharge the refrigerant:
30.1 Use the printout from the Mahle machine to determine how much oil to install.

30.2 Current POE bottles do not have level markings to measure fluid. Use an oil injector and calculate how much oil
to install.
Example: If the system needs 39 mL (1.32 oz), (if your oil measurement is in ounces (oz) convert oz to mL).
• 39 mL x 140 mm = 5460
• 5460 / 120 mL = 45.5 mm
• Measure 45.5 mm from the plunger, which is 39 mL

30.3 Launch the Techline Connect service diagnostic tool to open the system valves.
30.4 Follow the instructions on the Mahle machine screen prompts to add the POE oil and refrigerant back into the
system.
NOTE:
• Use the A/C Oil Injector (T/N 07-J-45037) with the R-1234yf A/C Oil Injector Hose (T/N 07-GE-50745).
• Do not use the Honda R-1234yf POE Oil Injector Hose.
• For more information, refer to Refrigerant Recovery and Recharging.
31. Install the underbody rear air rear deflector – rear. Do steps 1–5 of the Installation Procedure in Underbody Rear Air
Rear Deflector – Rear.
32. Reprogram the rear gate control module, do steps 1-3 in Reprogram Control Module in K194 Rear Gate Module:
Programming and Setup
33. Clear all DTCs.
34. Do the liftgate relearn if required. See Liftgate Calibration.
35. Check that the electrical features are operating properly.

Page 18 of 18