Honda_Odyssey_2001-2006

Engine

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Removal & Installation




NOTE
The engine and transaxle are removed from the vehicle as a unit.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the transaxle fluid.
  6.  
  7. Drain the engine oil.
  8.  
  9. Relieve fuel system pressure.
  10.  
  11. Remove or disconnect the following: Negative battery cableIntake manifold cover and ignition coil cover on 2002-04 modelsEvaporative Emissions (EVAP) control canister or vacuum hose, whichever appliesAir intake ductBatteryLeft engine wire harness connectorsRelay bracketBattery trayAccessory drive beltsAccelerator cableCruise control cableFuel linesBrake booster vacuum lineVacuum supply hosePowertrain Control Module (PCM) connectors and grommet. Pull the PCM harness through the firewall.Fuse/Relay box battery cableGround cablePower steering pumpStarter cable and harness clampRadiator hosesHeater hosesBypass hoseTransaxle oil cooler linesFront wheelsSplash shieldHeated Oxygen Sensor (HO2S) connectorExhaust front pipeStabilizer bar linksLower ball joints

    Negative battery cable
     
    Intake manifold cover and ignition coil cover on 2002-04 models
     
    Evaporative Emissions (EVAP) control canister or vacuum hose, whichever applies
     
    Air intake duct
     
    Battery
     
    Left engine wire harness connectors
     
    Relay bracket
     
    Battery tray
     
    Accessory drive belts
     
    Accelerator cable
     
    Cruise control cable
     
    Fuel lines
     
    Brake booster vacuum line
     
    Vacuum supply hose
     
    Powertrain Control Module (PCM) connectors and grommet. Pull the PCM harness through the firewall.
     
    Fuse/Relay box battery cable
     
    Ground cable
     
    Power steering pump
     
    Starter cable and harness clamp
     
    Radiator hoses
     
    Heater hoses
     
    Bypass hose
     
    Transaxle oil cooler lines
     
    Front wheels
     
    Splash shield
     
    Heated Oxygen Sensor (HO2S) connector
     
    Exhaust front pipe
     
    Stabilizer bar links
     
    Lower ball joints
     

  12.  
  13. Separate the inner CV-joints from the transaxle and support the axle halfshafts out of the work area with safety wire.
  14.  
  15. Remove or disconnect the following: Shift cable bracketShift cable coverShift control lever with cable attachedPower steering hose clamp and clipsTransaxle lower front mountTransaxle lower rear mountSteering rack and pinion gear. Support the steering gear with safety wire.

    Shift cable bracket
     
    Shift cable cover
     
    Shift control lever with cable attached
     
    Power steering hose clamp and clips
     
    Transaxle lower front mount
     
    Transaxle lower rear mount
     
    Steering rack and pinion gear. Support the steering gear with safety wire.
     

  16.  
  17. Attach a hoist to the engine lifting eyes and support the powertrain weight.
  18.  
  19. Remove or disconnect the following: Side engine mount bracketFront mount bracket support nut

    Side engine mount bracket
     
    Front mount bracket support nut
     

  20.  
  21. Matchmark the front subframe to the mounting points.
  22.  
  23. Remove or disconnect the following: Front subframeA/C compressor

    Front subframe
     
    A/C compressor
     

  24.  
  25. Lower the powertrain away from the vehicle.
  26.  

To install:



Click image to see an enlarged view

Fig. Sub-frame fastener locations and tightening torque-2001



Click image to see an enlarged view

Fig. Sub-frame fastener locations and tightening torque-2002-04

  1. Raise the powertrain into position.
  2.  
  3. Install or connect the following: A/C compressor. Tighten the bolts to 16 ft. lbs. (22 Nm).Front subframe. Use new bolts and tighten the 14mm bolts to 76 ft. lbs. (103 Nm). Tighten the front brace bolts to 54 ft. lbs. (74 Nm) and the rear brace bolts to 86 ft. lbs. (117 Nm).Transaxle lower front mount. Tighten the nuts to 28 ft. lbs. (38 Nm).Transaxle lower rear mount. Tighten the bolts to 28 ft. lbs. (38 Nm).Front mount bracket support nut. Tighten the nut to 40 ft. lbs. (54 Nm).Side engine mount bracket. Tighten the bracket bolts to 33 ft. lbs. (44 Nm) and the through bolt to 40 ft. lbs. (54 Nm).Steering rack and pinion gear. Tighten the bolts to 29 ft. lbs. (39 Nm).Power steering hose clamp and clipsShift control lever with cable attachedShift cable coverShift cable bracketAxle halfshafts. Use new circlips.Lower ball joints. Tighten the nuts to 43-51 ft. lbs. (59-69 Nm).Stabilizer bar links. Tighten the nuts to 58 ft. lbs. (78 Nm).Exhaust front pipeHO2S connectorSplash shieldFront wheelsTransaxle oil cooler linesRadiator hosesHeater hosesBypass hoseStarter cable and harness clampPower steering pumpGround cableFuse/Relay box battery cablePCM connectors and grommetVacuum supply hoseBrake booster vacuum lineCruise control cableAccelerator cableAccessory drive beltsFuel linesBattery trayRelay bracketLeft engine wire harness connectorsBatteryAir intake ductEVAP control canister hoseNegative battery cable

    A/C compressor. Tighten the bolts to 16 ft. lbs. (22 Nm).
     
    Front subframe. Use new bolts and tighten the 14mm bolts to 76 ft. lbs. (103 Nm). Tighten the front brace bolts to 54 ft. lbs. (74 Nm) and the rear brace bolts to 86 ft. lbs. (117 Nm).
     
    Transaxle lower front mount. Tighten the nuts to 28 ft. lbs. (38 Nm).
     
    Transaxle lower rear mount. Tighten the bolts to 28 ft. lbs. (38 Nm).
     
    Front mount bracket support nut. Tighten the nut to 40 ft. lbs. (54 Nm).
     
    Side engine mount bracket. Tighten the bracket bolts to 33 ft. lbs. (44 Nm) and the through bolt to 40 ft. lbs. (54 Nm).
     
    Steering rack and pinion gear. Tighten the bolts to 29 ft. lbs. (39 Nm).
     
    Power steering hose clamp and clips
     
    Shift control lever with cable attached
     
    Shift cable cover
     
    Shift cable bracket
     
    Axle halfshafts. Use new circlips.
     
    Lower ball joints. Tighten the nuts to 43-51 ft. lbs. (59-69 Nm).
     
    Stabilizer bar links. Tighten the nuts to 58 ft. lbs. (78 Nm).
     
    Exhaust front pipe
     
    HO2S connector
     
    Splash shield
     
    Front wheels
     
    Transaxle oil cooler lines
     
    Radiator hoses
     
    Heater hoses
     
    Bypass hose
     
    Starter cable and harness clamp
     
    Power steering pump
     
    Ground cable
     
    Fuse/Relay box battery cable
     
    PCM connectors and grommet
     
    Vacuum supply hose
     
    Brake booster vacuum line
     
    Cruise control cable
     
    Accelerator cable
     
    Accessory drive belts
     
    Fuel lines
     
    Battery tray
     
    Relay bracket
     
    Left engine wire harness connectors
     
    Battery
     
    Air intake duct
     
    EVAP control canister hose
     
    Negative battery cable
     

  4.  
  5. Fill the engine crankcase to the correct level.
  6.  
  7. Fill the transaxle to the correct level.
  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  
  13. Check the wheel alignment and adjust as necessary.
  14.  

2001-04 Models

NOTE
The engine and transaxle are removed from the vehicle as a unit.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the transaxle fluid.
  6.  
  7. Drain the engine oil.
  8.  
  9. Relieve fuel system pressure.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold cover and ignition coil cover
     
    Evaporative Emissions (EVAP) control canister or vacuum hose, whichever applies
     
    Air intake duct
     
    Battery
     
    Left engine wire harness connectors
     
    Relay bracket
     
    Battery tray
     
    Accessory drive belts
     
    Accelerator cable
     
    Cruise control cable
     
    Fuel lines
     
    Brake booster vacuum line
     
    Vacuum supply hose
     
    Powertrain Control Module (PCM) connectors and grommet. Pull the PCM harness through the firewall.
     
    Fuse/Relay box battery cable
     
    Ground cable
     
    Power steering pump
     
    Starter cable and harness clamp
     
    Radiator hoses
     
    Heater hoses
     
    Bypass hose
     
    Transaxle oil cooler lines
     
    Front wheels
     
    Splash shield
     
    Heated Oxygen Sensor (HO 2 S) connector
     
    Exhaust front pipe
     
    Stabilizer bar links
     
    Lower ball joints
     

  12.  
  13. Separate the inner CV-joints from the transaxle and support the axle halfshafts out of the work area with safety wire.
  14.  
  15. Remove or disconnect the following:

    Shift cable bracket
     
    Shift cable cover
     
    Shift control lever with cable attached
     
    Power steering hose clamp and clips
     
    Transaxle lower front mount
     
    Transaxle lower rear mount
     
    Steering rack and pinion gear. Support the steering gear with safety wire.
     

  16.  
  17. Attach a hoist to the engine lifting eyes and support the powertrain weight.
  18.  
  19. Remove or disconnect the following:

    Side engine mount bracket
     
    Front mount bracket support nut
     

  20.  
  21. Matchmark the front subframe to the mounting points.
  22.  
  23. Remove or disconnect the following:

    Front subframe
     
    A/C compressor
     

  24.  
  25. Lower the powertrain away from the vehicle.
  26.  

To install:

Click image to see an enlarged view

Fig. Sub-frame fastener locations and tightening torque-2001



Click image to see an enlarged view

Fig. Sub-frame fastener locations and tightening torque-2001-04

  1. Raise the powertrain into position.
  2.  
  3. Install or connect the following:

    A/C compressor. Tighten the bolts to 16 ft. lbs. (22 Nm).
     
    Front subframe. Use new bolts and tighten the 14mm bolts to 76 ft. lbs. (103 Nm). Tighten the front brace bolts to 54 ft. lbs. (74 Nm) and the rear brace bolts to 86 ft. lbs. (117 Nm).
     
    Transaxle lower front mount. Tighten the nuts to 28 ft. lbs. (38 Nm).
     
    Transaxle lower rear mount. Tighten the bolts to 28 ft. lbs. (38 Nm).
     
    Front mount bracket support nut. Tighten the nut to 40 ft. lbs. (54 Nm).
     
    Side engine mount bracket. Tighten the bracket bolts to 33 ft. lbs. (44 Nm) and the through bolt to 40 ft. lbs. (54 Nm).
     
    Steering rack and pinion gear. Tighten the bolts to 29 ft. lbs. (39 Nm).
     
    Power steering hose clamp and clips
     
    Shift control lever with cable attached
     
    Shift cable cover
     
    Shift cable bracket
     
    Axle halfshafts. Use new circlips.
     
    Lower ball joints. Tighten the nuts to 43-51 ft. lbs. (59-69 Nm).
     
    Stabilizer bar links. Tighten the nuts to 58 ft. lbs. (78 Nm).
     
    Exhaust front pipe
     
    HO 2 S connector
     
    Splash shield
     
    Front wheels
     
    Transaxle oil cooler lines
     
    Radiator hoses
     
    Heater hoses
     
    Bypass hose
     
    Starter cable and harness clamp
     
    Power steering pump
     
    Ground cable
     
    Fuse/Relay box battery cable
     
    PCM connectors and grommet
     
    Vacuum supply hose
     
    Brake booster vacuum line
     
    Cruise control cable
     
    Accelerator cable
     
    Accessory drive belts
     
    Fuel lines
     
    Battery tray
     
    Relay bracket
     
    Left engine wire harness connectors
     
    Battery
     
    Air intake duct
     
    EVAP control canister hose
     
    Negative battery cable
     

  4.  
  5. Fill the engine crankcase to the correct level.
  6.  
  7. Fill the transaxle to the correct level.
  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  
  13. Check the wheel alignment and adjust as necessary.
  14.  

2005-06 Models
  1. Make sure that you have the anti-theft codes for the radio and navigation system.
  2.  
  3. Drain the power steering fluid.
  4.  
  5. Relive the fuel system pressure.
  6.  
  7. Disconnect the battery.
  8.  
  9. Remove the grille.
  10.  
  11. Remove the battery.
  12.  
  13. Remove the intake manifold cover.
  14.  
  15. Remove the air cleaner housing and related tubes.
  16.  
  17. Remove the air intake duct.
  18.  
  19. Remove the battery tray.
  20.  
  21. Disconnect the starter cables.
  22.  
  23. Disconnect the fuel supply line.
  24.  
  25. Tag and disconnect all wires and hoses connected to the engine.
  26.  
  27. Remove the driver-s side console lower panel and pull back the carpet.
  28.  
  29. Remove the steering joint cover.
  30.  
  31. Lock the steering wheel and matchmark the steering shaft joint and the steering gear shaft.
  32.  
  33. Remove the bolt and disconnect the steering joint from the shaft.
    NOTE
    Do not turn the steering wheel with the joint disconnected.

  34.  
  35. Remove the PCM cover.
  36.  
  37. Remove the accessory drive belt.
  38.  
  39. Disconnect the power steering outlet hose at the pump.
  40.  
  41. Remove the power steering reservoir and disconnect the return hose.
  42.  
  43. Remove the radiator cap.
  44.  
  45. Raise the vehicle on a hoist.
  46.  
  47. Remove the front wheels.
  48.  
  49. Remove the splash shield.
  50.  
  51. Drain the cooling system.
  52.  
  53. Drain the transmission.
  54.  
  55. Drain the engine oil.
  56.  
  57. Remove the front exhaust pipe.
  58.  
  59. Disconnect the stabilizer links.
  60.  
  61. Disconnect the tie rod ends from the knuckles.
  62.  
  63. Disconnect the lower control arms from the knuckles.
  64.  
  65. Remove the halfshafts.
  66.  
  67. Disconnect the shift cable and remove the control lever.
  68.  
  69. Disconnect the power steering hoses from the gear.
  70.  
  71. Disconnect the power steering pressure switch.
  72.  
  73. Remove the nuts from the transmission lower front and rear mounts.
  74.  
  75. Lower the vehicle.
  76.  
  77. Disconnect the cooling fan wiring.
  78.  
  79. Remove the coolant reservoir.
  80.  
  81. Remove the fan and shroud.
  82.  
  83. Remove the upper and lower radiator hoses.
  84.  
  85. Remove the heater hoses.
  86.  
  87. Remove the transmission cooler hoses.
  88.  
  89. Remove the radiator.
  90.  
  91. Remove the A/C compressor and secure it aside without disconnecting the hoses.
  92.  
  93. Install engine hanger adapters VSB02C000022 on the engine support beams (A). Then, install the engine support hanger AAR-T-12566 with the adapters.

    Click image to see an enlarged view

    Fig. Engine support and hanger installed

  94.  
  95. Lift and support the engine with the support hanger and the balance bar VSB02C000019. Attach the front arm to the front cylinder head with a spacer (B) and the 10x1.25mm bolt (C). Attach the rear arm to the rear head with the 8x1.25mm bolt (D).
  96.  
  97. On the J35A6 engine, remove the vacuum hose (A) from the front engine mount stop (B), then remove the front engine mount bolt (C).

    Click image to see an enlarged view

    Fig. Front engine mount-J35A6 engine

  98.  
  99. On the J35A7 engine, disconnect the front active control engine mount actuator connector (A) and clamp (B), then remove the front engine mount stop (C) and the bolt (D).

    Click image to see an enlarged view

    Fig. Front engine mount-J35A7 engine

  100.  
  101. On the J35A6 engine, remove the heat shield and the rear engine mount bolts.
  102.  
  103. On the J35A7 engine, disconnect the rear ACM connector (A), remove the rear engine mount stop (B) and the rear engine mount bolt (C).

    Click image to see an enlarged view

    Fig. Rear engine mount-J35A7 engine

  104.  
  105. Raise the vehicle on the hoist.
  106.  
  107. Matchmark the subframe and body.

    Click image to see an enlarged view

    Fig. Subframe holding fixture-J35A6 and J35A7 engines

  108.  
  109. Attach the subframe holding fixture (A) by hanging the belt (B) over the front of the subframe, then secure the belt with the retaining pin (C).
  110.  
  111. Raise the jack and install the 4 bolts at the corners.
  112.  
  113. Remove the six 12x1.25mm bolts (A) securing the subframe stiffeners (B), the 4 subframe mounting bolts (C) and the stiffeners. Lower the subframe (D).
  114.  
  115. Lower the vehicle.
  116.  
  117. Attach a chain hoist to the engine hook and the transmission hook. Lift the engine/transmission assembly until it is supported by the hoist, then, remove the engine support hanger and adapters.
  118.  
  119. Remove the mounting bolts from the upper half of the side engine mount bracket.
  120.  
  121. Check that all hoses, wires and lines are free from the engine.
  122.  
  123. Slowly lower the engine/transmission assembly about 6 inches. Check for anything that might hinder removal, then remove the engine/transmission assembly.
  124.  
  125. Raise the vehicle and remove the unit.
  126.  

To install:

  1. Install the engine mount brackets and tighten to the torques shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Engine mount bracket torques-J35A6 and J35A7 engines

  2.  
  3. Position the engine/transmission under the vehicle. Make sure they are aligned and lower the vehicle until it is properly positioned. Using the hoist, raise the assembly into place.
    NOTE
    Install the mounting bolts/nuts in the order given in the following steps. Otherwise, noise and vibration will result.

  4.  
  5. Install the engine hanger adapters on the end of the support beams. Install the support hanger with adapters.
  6.  
  7. Install the support hanger and balance bar to the front and rear heads.
  8.  
  9. Install NEW mounting bolts into the upper half of the engine mount bracket. Torque to 33 ft. lbs. (44 Nm).
  10.  
  11. Remove the chain hoist.
  12.  
  13. Raise the subframe into position and loosely install all bolts.

    Click image to see an enlarged view

    Fig. Subframe installation torques-J35A6 and J35A7 engines

  14.  
  15. Align all reference marks and tighten the bolts as shown in the accompanying illustration.
  16.  
  17. Remove the subframe support tool.
  18.  
  19. Install the transmission lower rear mount. Torque to 28 ft. lbs. (38 Nm).
  20.  
  21. On the J35A6 engine, tighten the rear engine bolts and heat shield. Torque the mount bolts to 31 ft. lbs. (42 Nm); torque the heat shield bolts to 43 ft. lbs. (58 Nm).
  22.  
  23. On the J35A7 engine, torque the rear engine mount bolt to 40 ft. lbs. (54 Nm), then torque the rear engine stop nuts to 54 ft. lbs. (73 Nm). Connect the ACM.
  24.  
  25. On the J35A6 engine, tighten the front mount bolt to 40 ft. lbs. (54 Nm), then the front mount stop nuts to 54 ft. lbs. (73 Nm). Connect the vacuum hose.
  26.  
  27. On the J35A7 engine, tighten the front engine mount bolt to 40 ft. lbs. (54 Nm), then tighten the front mount stop nuts to 54 ft. lbs. (73 Nm). Connect the ACM actuator and install the harness clamp.
  28.  
  29. Loosen the bolts at the upper half of the side mount and retighten them to 33 ft. lbs. (44 Nm).
  30.  
  31. Remove the engine support pieces.
  32.  
  33. Install the A/C compressor. Torque to 16 ft. lbs. (22 Nm).
  34.  
  35. Install the radiator.
  36.  
  37. The remainder of installation is the reverse of removal. Observe the following torques:

    Exhaust pipe-to-manifold: 40 ft. lbs. (54 Nm)
     
    Exhaust pipe hanger nut: 16 ft. lbs. (22 Nm)
     
    Exhaust pipe-to-converter: 25 ft. lbs. (33 Nm)
     
    Steering joint bolt: 21 ft. lbs. (28 Nm)
     
    Battery tray bolts: 16 ft. lbs. (22 Nm)
     

  38.  
  39. Refill all fluids and check for leaks and proper operation.
  40.  

 
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