Honda Pilot - 2003-2005

Thermostat

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Removal & Installation



2003-04 Models
  1. Make sure you have the anti-theft codes for the radio and navigation system, then write down the frequencies for the radio's preset buttons.
  2.  
  3. Disconnect the negative cable from the battery first, and then the positive cable.
  4.  
  5. Remove the battery.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove the thermostat cover, then remove the thermostat.

    Click image to see an enlarged view

    Fig. Exploded view of the thermostat-2003-04 models

  10.  

To install:

  1. Install the thermostat with new rubber seal.
  2.  
  3. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
  4.  
  5. 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.  

  6.  
  7. Clean up any spilled engine coolant.
    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.
     

  8.  
  9. 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.  

  10.  
  11. 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.  

  12.  
  13. Reset the clock.
  14.  
  15. Enter the anti-theft codes for the radio and the navigation system, then enter the radio station presets.
  16.  

2005 Models
  1. Make sure you have the anti-theft codes for the radio and navigation system, and write down the radio station presets.
  2.  
  3. Disconnect the negative cable from the battery.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Disconnect the breather pipe (A), then remove the intake air duct (B).

    Click image to see an enlarged view

    Fig. Disconnect the breather pipe (A) and remove the intake air duct (B)-2005 models

  8.  
  9. Remove the bolt (A) securing the harness cover, then remove harness cover.

    Click image to see an enlarged view

    Fig. Remove the bolt (A) securing the harness cover, then remove harness cover-2005 models

  10.  
  11. Remove the thermostat cover (A), then remove the thermostat (B).
  12.  

To install:

  1. Face the pin (C) toward the upside, install the thermostat with new rubber seal (D).

    Click image to see an enlarged view

    Fig. View of the thermostat cover (A) and thermostat (B). When installing, make sure to face the pin (C) upward and use a new rubber seal (D)-2005 models

  2.  
  3. Install the harness cover.
  4.  
  5. Install the intake air duct, then connect the breather pipe.
  6.  
  7. Connect the negative cable to the battery.
  8.  
  9. 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.  

  10.  
  11. Clean up any spilled engine coolant.
  12.  
  13. 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.  

  14.  
  15. Enter the anti-theft codes for the radio and the navigation system, and enter the radio station presets. Set the clock.
  16.  

 
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