Honda Pilot - 2003-2005

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Drive belts
     
    Power steering and pump
     
    Power steering hose clamp
     
    Alternator
     
    Intake manifold cover
     
    Ignition coil covers
     
    Ignition coils
     
    Timing belt
     
    Intake manifold
     
    Fuel injector connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Crankshaft Position (CKP) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    Exhaust Gas Recirculation (EGR) connector
     
    Radiator fan switch connectors
     
    Valve Lift Electronic Control (VTEC) solenoid valve connector and oil pressure switch connections
     
    Oil pressure switch connector
     
    Two Air/Fuel (A/F) connectors
     
    Two Heated Oxygen (HO 2 S) sensor connectors
     
    Radiator hoses
     
    Heater hose
     
    Water bypass hose
     
    Harness bracket
     
    EVAP canister hose
     
    Fuel feed and return lines
     
    Fuel rails
     
    Exhaust manifolds
     
    Water passage
     
    Vacuum hoses from the intake air bypass control valve
     
    Ground cable
     
    Camshaft pulleys and back covers
     
    Valve covers
     

  8.  
  9. Loosen the cylinder head bolts in sequence and 1 / 3 turns until all bolts are loose.
  10.  
  11. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Pilot

  12.  

To install:

Click image to see an enlarged view

Fig. Crankshaft timing belt sprocket TDC marks. Align sprocket mark (A) with pointer (B)-Pilot



Click image to see an enlarged view

Fig. Camshaft TDC marks. Align sprocket mark (A) with the back cover pointer (B)-Pilot

  1. Align the crankshaft and camshaft sprocket TDC marks as shown.
  2.  
  3. Install the cylinder heads with new gaskets.
  4.  
  5. Apply clean engine oil to the cylinder head bolt threads and flanges.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-Pilot

  6.  
  7. Tighten the cylinder head bolts in sequence as follows:
    1. Step 1: 29 ft. lbs. (39 Nm).
    2.  
    3. Step 2: 51 ft. lbs. (69 Nm).
    4.  
    5. Step 3: 72 ft. lbs. (98 Nm).
    6.  

  8.  
  9. Install or connect the following:

    Timing belt and adjust the valve clearance
     
    Valve covers
     
    Exhaust manifolds
     
    Water passage
     
    Fuel rails
     
    EVAP canister hose
     
    Vacuum hoses to the intake air bypass control valve
     
    Fuel feed and return lines
     
    Heater hose
     
    Radiator hoses
     
    Intake manifold
     
    Two A/F connectors
     
    Two HO 2 S sensor connectors
     
    Oil pressure switch connector
     
    VTEC solenoid valve connector and oil pressure switch connections
     
    EGR connector
     
    CMP sensor connector
     
    CKP sensor connector
     
    Radiator fan switch connectors
     
    ECT sensor connector
     
    Fuel injector connectors
     
    Ignition coils
     
    Power steering pump and belt
     
    Power steering hose clamp
     
    Alternator
     
    Ground cable
     
    Ignition coil covers
     
    Intake manifold cover
     
    Alternator belt
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine and check for leaks.
  14.  

 
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