Honda Pilot - 2003-2005

Cylinder Head Cover

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Removal & Installation



2003-04 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold, as outlined in this section.
  4.  
  5. Remove the six ignition coils, as outlined in the Engine Electrical Section.
  6.  
  7. Remove the cylinder head cover(s).

    Click image to see an enlarged view

    Fig. Cylinder head cover tightening sequence-

  8.  

To install:


WARNING
Take care not damage the spark plug seal when installing the cylinder head cover.

  1. Before installing the cylinder head cover, clean the cylinder head contacting surfaces with a shop towel.
  2.  
  3. Inspect the spark plug seals for damage and replace if damaged.
  4.  
  5. Install the cylinder head covers. Tighten the nuts, in sequence, in two or three steps. In the final step, tighten all nuts, in sequence, to 8.7 ft. lbs. (12 Nm).
  6.  
  7. Install the six ignition coils.
  8.  
  9. Install the intake manifold.
  10.  
  11. Connect the negative battery cable.
  12.  

2005 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold, as outlined in this section.
  4.  
  5. Remove the six ignition coils, as outlined in the Engine Electrical Section.
  6.  
  7. Remove the three bolts (A) securing the harness holder and bracket, and remove the harness clamp (B) and dipstick (C).

    Click image to see an enlarged view

    Fig. Remove the three bolts (A) securing the harness holder and bracket, and remove the harness clamp (B) and dipstick (C)

  8.  
  9. Disconnect the three injector connectors from the injectors on the cylinder head.
  10.  
  11. Remove the power steering hose bracket mounting bolt (A) and the harness holder mounting bolts (B).
  12.  
  13. Remove the harness clamps (C) and breather hose (D).

    Click image to see an enlarged view

    Fig. Remove the power steering hose bracket mounting bolt (A) and the harness holder mounting bolts (B). Then, remove the harness clamps (C) and breather hose (D)

  14.  
  15. Remove the cylinder head cover.
  16.  
  17. Clean the head cover contacting surfaces with a shop towel.
  18.  
  19. Visually check the spark plug seals for damage. Replace if necessary.
  20.  

To install:

  1. Set the spark plug seals (A) on the spark plug tubes, and install the cylinder head cover (B).
  2.  
  3. Inspect the cover washer (C). Replace any washer that is damaged or deteriorated.

    Click image to see an enlarged view

    Fig. Cylinder head cover installation-front shown



    Click image to see an enlarged view

    Fig. Cylinder head cover installation-rear shown

  4.  
  5. Tighten the bolts in two or three steps. In the final step tighten all bolts, in sequence, to 8.7 ft. lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-2005 models

  6.  
  7. Tighten the harness holder mounting bolts (A) and the power steering hose bracket mounting bolt (B).
  8.  
  9. Install the harness clamps (C) and breather hose (D).

    Click image to see an enlarged view

    Fig. Tighten the harness holder mounting bolts (A) and the power steering hose bracket mounting bolt (B). Then, install the harness clamps (C) and breather hose (D)

  10.  
  11. Connect the three injector connectors to the injectors on the cylinder head.
  12.  
  13. Tighten the three bolts (A) securing the harness holder and bracket, then install the harness clamp (B) and dipstick (C).

    Click image to see an enlarged view

    Fig. Tighten the three bolts (A) securing the harness holder and bracket, then install the harness clamp (B) and dipstick (C)

  14.  
  15. Install the six ignition coils.
  16.  
  17. Install the intake manifold.
  18.  
  19. Connect the negative battery cable.
  20.  

 
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