Honda Pilot - 2003-2005

Radiator & Engine Fan

Print

Removal & Installation




WARNING
Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.


NOTE
Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

  1. Remove the radiator cover.
  2.  
  3. Make sure you have the anti-theft codes for the radio and the navigation system, then write down the frequencies for the radio's preset buttons.
  4.  
  5. Disconnect the negative cable from the battery first, then disconnect the positive cable.
  6.  
  7. Remove the battery and battery tray.
  8.  
  9. Drain the engine coolant.
  10.  
  11. Remove the harness clamps, and engine wire harness connectors from the battery base.
  12.  
  13. Remove relay bracket.
  14.  
  15. Remove the three mounting bolts, and loosen the mounting bolt, then remove the battery base.
  16.  
  17. Remove the upper radiator hose.
  18.  
  19. Remove the radiator upper brackets/cushions (A) and condenser brackets (B).

    Click image to see an enlarged view

    Fig. Radiator upper brackets/cushions (A) and condenser brackets (B) mounting

  20.  
  21. Disconnect the compressor clutch connector (A), fan motor connectors (B), and radiator fan switch C connector (C).
  22.  
  23. Remove the harness clamps (D).

    Click image to see an enlarged view

    Fig. View of the compressor clutch connector (A), fan motor connectors (B), fan switch C connector (C) and harness clamps (D)

  24.  
  25. Remove the bulkhead bracket.

    Click image to see an enlarged view

    Fig. Bulkhead bracket mounting

  26.  
  27. Remove the two bolts (A) securing the radiator fan shroud, then remove the radiator fan shroud assembly (B) from the battery side.
  28.  
  29. Remove the two bolts (C), and loosen the two bolts (D) securing the condenser fan shroud, then remove the condenser fan shroud assembly (E) from the battery side.

    Click image to see an enlarged view

    Fig. Remove the two bolts (A) securing the radiator fan shroud, then remove the radiator fan shroud assembly (B) from the battery side. Then, remove the two bolts (C), and loosen the two bolts (D) securing the condenser fan shroud, then remove the condenser fan shroud assembly (E) from the battery side

  30.  
  31. Remove the lower radiator hose and automatic transmission fluid (ATF) cooler hoses. Plug the ATF cooler hoses and lines.
  32.  
  33. Pull up the radiator assembly (A), then remove the lower cushions (B).
  34.  
  35. Remove the radiator fan switch C (C), radiator cap (D) and drain plug (E).

    Click image to see an enlarged view

    Fig. Pull up the radiator assembly (A), then remove the lower cushions (B), then remove the radiator fan switch C (C), radiator cap (D) and drain plug (E)

  36.  

To install:

  1. Install the radiator in the reverse order of removal.
  2.  
  3. Install the bulkhead bracket in the reverse order of removal. Apply body paint to the bulkhead bracket mounting bolts.
  4.  
  5. Set the upper and lower cushions securely.
  6.  
  7. Fill the radiator with engine coolant, and bleed the air, as follows.
    1. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. Start the engine. Hold the engine speed at 1,500 rpm until it warms up (the radiator fan comes on at least twice). Make sure the thermostat is open.
      NOTE
      Always use Honda All Season Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50% antifreeze and 50% water. Pre-mixing is not required. The Engine Coolant Refill Capacity (including the reservoir capacity of 0.8 l (0.8 US qt) is 7.0 l (7.4 US qt).

    2.  
    3. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    4.  
    5. Set the climate control or heater control panel to maximum cool. Start the engine. Hold the engine speed at 1,500 rpm for 5 minutes, then turn off the engine.
    6.  
    7. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    8.  
    9. Set the climate control or heater control panel to maximum heat. Start the engine. Hold the engine speed at 1,500 rpm for 5 minutes, then turn off the engine.
    10.  
    11. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    12.  
    13. Set the climate control or heater control panel to maximum cool. Start the engine. Hold the engine speed at 1,500 rpm for 3 minutes, then turn off the engine.
    14.  
    15. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    16.  
    17. Set the climate control or heater control panel to maximum heat. Start the engine. Hold the engine speed at 1,500 rpm for 3 minutes, then turn off the engine.
    18.  
    19. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    20.  
    21. Repeat steps O. through R. until the coolant level does not change in the radiator, then install the radiator cap loosely.
    22.  
    23. Set the climate control or heater control panel to maximum cool. Start the engine. Hold the engine speed at 2,500 rpm for 1 minute.
    24.  

  8.  
  9. Adjust the engine hood latch, as follows:
    1. Adjust the hood (A) alignment in this sequence.
    2.  
    3. Adjust the hood right and left, as well as forward and rearward, by using the elongated holes on the hood hinge(B).
    4.  
    5. Turn the hood edge cushions (C), as necessary, to make the hood fit flush with the body at the front and side edges.
    6.  
    7. Adjust the hood latch (D) to obtain the proper height at the forward edge, and move the hood latch right or left until the striker (E) is centered in the hood latch.
    8.  
    9. Tighten each bolt securely.
    10.  
    11. Check that the hood opens properly and locks securely.
    12.  
    13. For some models, check that the security system operates properly with the hood opened and closed.
    14.  
    15. Apply body paint to the hinge mounting bolts and around the hinges.

      Click image to see an enlarged view

      Fig. Engine hood latch adjustment

    16.  

  10.  
  11. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
    NOTE
    For the PCM to learn the engine idle characteristics, the idle learn procedure must be done. Do the idle learn procedure whenever you do any of these actions:



    Disconnect the battery.
     
    Replace or clean the throttle body.
     
    Replace the idle air control (IAC) valve.
     
    Replace the PCM.
     
    Reset the PCM.
     

  12.  
  13. Perform the idle learn procedure, as follows:
    1. Make sure all electrical items (A/C, audio, rear window defogger, lights, etc.) are off.
    2.  
    3. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194ºF (90ºC).
    4.  
    5. Let the engine idle for a minimum of 5 minutes with no load.
      NOTE
      If the radiator fan cycles during this time, do not include its running time in the 5 minutes.

    6.  

  14.  
  15. Perform the power window control unit reset procedure
    1. Turn the ignition switch OFF, then back ON (II).
    2.  
    3. Move the driver's window all the way down by holding the driver's switch firmly down to the second detent, when the window reaches the bottom, hold the driver's window switch in the AUTO DOWN position for 2 seconds.
    4.  
    5. Move the driver's window all the way up without stopping by holding the driver's switch firmly up to the second detent, when the window reaches the top, hold the driver's window switch in the AUTO UP position for 2 seconds.
    6.  
    7. If the window does not work in AUTO, reset the power window master switch according to the above procedures again.
    8.  

  16.  
  17. Reset the clock.
  18.  
  19. Enter the anti-theft codes for the radio and the navigation system, then enter the radio station presets.
  20.  

 
label.common.footer.alt.autozoneLogo