Honda Pilot - 2003-2005

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 power steering system.
  6.  
  7. Drain the transaxle fluid.
  8.  
  9. Drain the engine oil.
  10.  
  11. Relieve fuel system pressure.
  12.  
  13. Remove or disconnect the following: Negative battery cableBatteryIntake and ignition coil coversAir intake ductLeft engine wire harness connectorsRelay bracketBattery and trayStarter cable and harness clampAccelerator cableCruise control cableFuel linesEVAP canister hose

    Negative battery cable
     
    Battery
     
    Intake and ignition coil covers
     
    Air intake duct
     
    Left engine wire harness connectors
     
    Relay bracket
     
    Battery and tray
     
    Starter cable and harness clamp
     
    Accelerator cable
     
    Cruise control cable
     
    Fuel lines
     
    EVAP canister hose
     

  14.  
  15. Remove the drivers side center console lower panel and pull back the cover to access steering joint cover. Steering joint boltPowertrain Control Module (PCM) connectorsHeated Oxygen (HO2S) sensor connector and grommet. Pull the PCM harness through the firewall.Brake booster vacuum lineClamps and clips from power steering hosesFuse/relay box battery cableAccessory drive beltsFront wheelsSplash shieldFront sub-frame stiffenerExhaust front pipePropeller shaftShift control cableTransfer assemblyBall jointsStabilizer bar linksHalfshaftsPower steering hose and pressure switch connectorTransaxle lower front mountTransaxle lower rear mountA/C compressorHeater hosesRadiator hosesGround cableTransaxle oil cooler linesRadiator

    Steering joint bolt
     
    Powertrain Control Module (PCM) connectors
     
    Heated Oxygen (HO2S) sensor connector and grommet. Pull the PCM harness through the firewall.
     
    Brake booster vacuum line
     
    Clamps and clips from power steering hoses
     
    Fuse/relay box battery cable
     
    Accessory drive belts
     
    Front wheels
     
    Splash shield
     
    Front sub-frame stiffener
     
    Exhaust front pipe
     
    Propeller shaft
     
    Shift control cable
     
    Transfer assembly
     
    Ball joints
     
    Stabilizer bar links
     
    Halfshafts
     
    Power steering hose and pressure switch connector
     
    Transaxle lower front mount
     
    Transaxle lower rear mount
     
    A/C compressor
     
    Heater hoses
     
    Radiator hoses
     
    Ground cable
     
    Transaxle oil cooler lines
     
    Radiator
     

  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 Sub-frame to the mounting points.
  22.  
  23. Remove or disconnect the following: Front subframeAll remaining hoses and electrical connections

    Front subframe
     
    All remaining hoses and electrical connections
     

  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-Pilot

  1. Raise the powertrain into position.
  2.  
  3. Installation is the reverse of removal but please note the following steps: A/C compressor 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 nuts to 28 ft. lbs. (38 Nm)Transaxle lower rear mount bolts to 28 ft. lbs. (38 Nm)Front mount bracket support nut to 40 ft. lbs. (54 Nm)Side engine mount bracket bolts to 33 ft. lbs. (44 Nm) and the through bolt to 40 ft. lbs. (54 Nm)

    A/C compressor 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 nuts to 28 ft. lbs. (38 Nm)
     
    Transaxle lower rear mount bolts to 28 ft. lbs. (38 Nm)
     
    Front mount bracket support nut to 40 ft. lbs. (54 Nm)
     
    Side engine mount bracket bolts to 33 ft. lbs. (44 Nm) and the through bolt to 40 ft. lbs. (54 Nm)
     

  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. Fill the power steering system.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Check the wheel alignment and adjust as necessary.
  16.  


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 power steering system.
  6.  
  7. Drain the transaxle fluid.
  8.  
  9. Drain the engine oil.
  10.  
  11. Relieve fuel system pressure.
  12.  
  13. Remove or disconnect the following:

    Negative battery cable
     
    Battery
     
    Intake and ignition coil covers
     
    Air intake duct
     
    Left engine wire harness connectors
     
    Relay bracket
     
    Battery and tray
     
    Starter cable and harness clamp
     
    Accelerator cable
     
    Cruise control cable
     
    Fuel lines
     
    EVAP canister hose
     

  14.  
  15. Remove the drivers side center console lower panel and pull back the cover to access steering joint cover.

    Steering joint bolt
     
    Powertrain Control Module (PCM) connectors
     
    Heated Oxygen (HO 2 S) sensor connector and grommet. Pull the PCM harness through the firewall.
     
    Brake booster vacuum line
     
    Clamps and clips from power steering hoses
     
    Fuse/relay box battery cable
     
    Accessory drive belts
     
    Front wheels
     
    Splash shield
     
    Front sub-frame stiffener
     
    Exhaust front pipe
     
    Propeller shaft
     
    Shift control cable
     
    Transfer assembly
     
    Ball joints
     
    Stabilizer bar links
     
    Halfshafts
     
    Power steering hose and pressure switch connector
     
    Transaxle lower front mount
     
    Transaxle lower rear mount
     
    A/C compressor
     
    Heater hoses
     
    Radiator hoses
     
    Ground cable
     
    Transaxle oil cooler lines
     
    Radiator
     

  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
     
    All remaining hoses and electrical connections
     

  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-Pilot

  1. Raise the powertrain into position.
  2.  
  3. Installation is the reverse of removal but please note the following steps:

    A/C compressor 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 nuts to 28 ft. lbs. (38 Nm)
     
    Transaxle lower rear mount bolts to 28 ft. lbs. (38 Nm)
     
    Front mount bracket support nut to 40 ft. lbs. (54 Nm)
     
    Side engine mount bracket bolts to 33 ft. lbs. (44 Nm) and the through bolt to 40 ft. lbs. (54 Nm)
     

  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. Fill the power steering system.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Check the wheel alignment and adjust as necessary.
  16.  

 
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