Honda Pilot - 2003-2005

Electric Cooling Fan Switch

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Removal & Installation



2003-04 Models
Switch A
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Disconnect radiator fan switch A connector, then remove radiator fan switch A (A).

    Click image to see an enlarged view

    Fig. When installing radiator fan switch A (A), use a new O-ring (B)-2003-04 models

  6.  

To install:

  1. Install radiator fan switch A with a new O-ring (B). Tighten to 17 ft. lbs. (24 Nm).
  2.  
  3. Fill the radiator with engine coolant and bleed the air, as follows:
  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.
      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 qts) is 7.4 qts.

    2.  
    3. 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.
    4.  
    5. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    6.  
    7. 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.
    8.  
    9. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    10.  
    11. 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.
    12.  
    13. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    14.  
    15. 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.
    16.  
    17. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    18.  
    19. 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.
    20.  
    21. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    22.  
    23. Repeat the steps h. through k. until the coolant level does not change in the radiator, then install the radiator cap loosely.
    24.  
    25. 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.
    26.  
    27. Set the climate control or heater control panel to maximum heat, and select high speed heat mode on the rear control panel. Measure the temperature of the air from the rear floor vent for 2 or 3 minutes.
    28.  
    29. Make sure the temperature is above the standard line of the graph shown. If the temperature is below the standard line, repeat steps h. through k. several more times. Then loosely install the radiator cap and recheck.

      Click image to see an enlarged view

      Fig. Temperature graph-2003-04 models

    30.  
    31. Make sure you do not hear the sound of water flowing near the rear heater unit. If you hear water flowing, repeat steps h. through k. several more times. Then loosely install the radiator cap and recheck.
    32.  
    33. Fill the reserve tank with Honda All Season Antifreeze/Coolant Type 2 up to the MAX mark on the tank, then add an extra 0.4 qts. of coolant.
    34.  

  6.  

Switch B
  1. 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.
      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 qts) is 7.4 qts.

    2.  
    3. 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.
    4.  
    5. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    6.  
    7. 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.
    8.  
    9. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    10.  
    11. 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.
    12.  
    13. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    14.  
    15. 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.
    16.  
    17. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    18.  
    19. 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.
    20.  
    21. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    22.  
    23. Repeat the steps h. through k. until the coolant level does not change in the radiator, then install the radiator cap loosely.
    24.  
    25. 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.
    26.  
    27. Set the climate control or heater control panel to maximum heat, and select high speed heat mode on the rear control panel. Measure the temperature of the air from the rear floor vent for 2 or 3 minutes.
    28.  
    29. Make sure the temperature is above the standard line of the graph shown. If the temperature is below the standard line, repeat steps h. through k. several more times. Then loosely install the radiator cap and recheck.

      Click image to see an enlarged view

      Fig. Temperature graph-2003-04 models

    30.  
    31. Make sure you do not hear the sound of water flowing near the rear heater unit. If you hear water flowing, repeat steps h. through k. several more times. Then loosely install the radiator cap and recheck.
    32.  
    33. Fill the reserve tank with Honda All Season Antifreeze/Coolant Type 2 up to the MAX mark on the tank, then add an extra 0.4 qts. of coolant.
    34.  

  2.  

Switch C
  1. 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.
      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 qts) is 7.4 qts.

    2.  
    3. 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.
    4.  
    5. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    6.  
    7. 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.
    8.  
    9. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    10.  
    11. 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.
    12.  
    13. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    14.  
    15. 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.
    16.  
    17. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    18.  
    19. 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.
    20.  
    21. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2, if needed.
    22.  
    23. Repeat the steps h. through k. until the coolant level does not change in the radiator, then install the radiator cap loosely.
    24.  
    25. 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.
    26.  
    27. Set the climate control or heater control panel to maximum heat, and select high speed heat mode on the rear control panel. Measure the temperature of the air from the rear floor vent for 2 or 3 minutes.
    28.  
    29. Make sure the temperature is above the standard line of the graph shown. If the temperature is below the standard line, repeat steps h. through k. several more times. Then loosely install the radiator cap and recheck.

      Click image to see an enlarged view

      Fig. Temperature graph-2003-04 models

    30.  
    31. Make sure you do not hear the sound of water flowing near the rear heater unit. If you hear water flowing, repeat steps h. through k. several more times. Then loosely install the radiator cap and recheck.
    32.  
    33. Fill the reserve tank with Honda All Season Antifreeze/Coolant Type 2 up to the MAX mark on the tank, then add an extra 0.4 qts. of coolant.
    34.  

  2.  

Testing



2003-04 Models

NOTE
Bleed air from the cooling system after installing the radiator fan switch.

  1. Remove radiator fan switch A from the water passage, remove radiator fan switch B from the cylinder head, and remove radiator fan switch C from the radiator, as outlined later in this section.
  2.  
  3. Suspend each radiator fan switch (A) in a container of water as shown.
  4.  
  5. Heat the water, and check the temperature with a thermometer (B). Do not let the thermometer touch the bottom of the hot container.

    Click image to see an enlarged view

    Fig. Suspend the fan switch (A) in a container of water. Heat the water, then check the temperature with a thermometer (B). Do not let the thermometer touch the bottom of the hot container, or you will get a false reading-2003-04 models

  6.  
  7. Measure the continuity between terminal 1 and terminal 2 according to the accompanying table.

    Click image to see an enlarged view

    Fig. Radiator fan switch continuity table-2003-04 models

  8.  

 
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