This write up covers the installation of the climate control cover as sold by Todd (CRX Toad on Honda-Tech, stang65fst on Ebay. Beware of imitations, we are the original!). It gives your broken climate control a new look without spending hundreds of dollars on a new unit. It is not intended to provide structural support to the climate control unit; it is only a cosmetic piece. If your climate control unit is damaged or broken, it must be repaired prior to using the cover. This write up will detail the removal and repair of a damaged unit so the cover may be installed.
This repair was performed on a 1991 Honda CRX Si. Other years or trim levels may be different. Your mileage may vary, parental discretion is advised. If you are unclear or uncomfortable with any procedure in this write up, seek outside assistance, either from the Helms manual or an *experienced* friend.
If you don't have a climate control plate and are interested in ordering one, contact Todd at firstname.lastname@example.org, on Honda-Tech through his screen name, CRX Toad, or on Ebay by the seller name stang65fst.
Step 1: Things
#1 Phillips Head Screwdriver
#2 Phillips Head Screwdriver
Small Flat Head Screwdriver
Climate Control Cover Plate
2 Part Epoxy
Step 2: Did You Get That Thing
Examine the climate control unit to make sure it's broken and you're not wasting your time. Looks broken to me. Also make sure you have the climate control plate, so as not to feel stupid once you take it apart.
Step 3: Disassembling That Thing
Remove the shift knob by twisting it counterclockwise. Remove the six screws in the center console. There are two on either side of the radio, two by the shifter, one under the steering wheel, and one inside the glove box. Carefully remove the center console by pulling it out. Be careful you don't damage the shifter boot on the shifter.
Step 4: Getting to That Thing
You can now see how the climate control unit is mounted, and how the plate will fit onto the unit. Remove the three screws holding the climate control unit to the center console bracket. Remove the radio. Remove the four screws holding the radio surround and lower pocket to the center console bracket. Remove the radio surround by pulling it outward. Disconnect the 4 pin connector on the back of the radio surround.
Step 5: You Got That Thing
Remove the screw underneath the climate control unit holding it to the bracket. Remove the bracket. Disconnect the three connectors on the back of the climate control unit. You do not need to disconnect the yellow connector on the right side of the unit. Carefully remove the climate control unit. Make sure the control cables don't get stuck, and pivot the rear of the unit downward and slide it out of the center console bracket.
Step 6: Disconnecting That Thing
Examine the rear of the unit where the control cables attach to the unit. You will remove this section to allow easier access to the unit. Remove the temperature control knob by pulling it out. Remove the two screws holding the control cable housing to the climate control unit. The control cable housing should pop off the unit. If it doesn't. give a little tap to encourage it. The removed climate control unit in all its glory.
Step 7: Repairing That Thing
Depending on the amount of damage on your climate control unit, you may want to take it apart further to fix other cracks. I could see a couple, so I decide to investigate further. Remove the temperature control light by removing the screw and carefully prying it out. Remove the fan speed control switch by carefully prying off the knob. Remove the screws holding it to the unit. In my case, there was one screw left, and it was halfway out anyway, making this easier than it should be. Using the epoxy, reinforce any cracks in the housing. Flexing the unit back and forth can help work the epoxy into the crack. Once you have repaired all the cracks, it's time to get the whole thing back in one piece. I used a 2 part epoxy due to the fact that I had a lot of space to fill, and super glue just isn't up to the task. Mock up the pieces and get an idea for how they will fit together. You don't want any surprises when the glue is curing. This is it, the big moment. Apply the epoxy to the surface that will mate with the other piece and put them together. Then go play Halo 2 for a few hours while it sets. When you return, it should look something like this.
Step 8: Covering That Thing
Test fit the plate over the climate control, making sure it lays flat and all the edges line up. Pay attention to the sides, the plate should sit in the face of the unit, butting up against the mounting tabs. Now, put an extremely thin bead of 2 part epoxy around all the textured surfaces of the face. You don't need much at all; just barely any will be plenty as the plate will spread it out when you put it on. Carefully lay the plate on the unit and gently press down on all the surfaces to spread the epoxy between them evenly. Go play more Halo, and when you return, you should have something like this.
Step 9: Reinstalling That Thing
Installation is the reverse of removal. Be careful when reinstalling the unit, you don't want to undo all your hard work by snapping it in half again. Once you are finished, you should have something that looks like this. Compare to what we started with, I'd say it looks pretty good.