Pilot 2006-2008

Cylinder Head 2

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Removal & Installation



J35Z1 Engine

Specific to:

Honda Pilot 2006-2008


NOTE
Be sure that you have the anti-theft codes for the audio system and navigation system, if equipped. Record the audio presets.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Turn the ignition switch OFF.
  4.  
  5. Disconnect and isolate the negative battery cable. Wait 3 minutes for the system capacitor to discharge before performing any service.
  6.  
  7. Disconnect the positive battery cable.
    WARNING
    To avoid damaging the cylinder head be sure that the engine is cold before loosening the cylinder head bolts.

  8.  
  9. Properly relieve the fuel system pressure.
  10.  
  11. Drain the engine coolant. Properly dispose of used coolant.
  12.  
  13. Remove the drive belt.
  14.  
  15. Remove the power steering pump and the bolt securing the pump hose bracket.
  16.  
  17. Remove the alternator.
  18.  
  19. Remove the intake manifold.

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    Fig. Intake manifold and related components-J35Z1 engine

  20.  
  21. Remove the ignition coils.
  22.  
  23. Remove the timing belt.

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    Fig. Splash shield removal points



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    Fig. Timing belt and related components-J35Z1 engine

  24.  
  25. Disconnect the injector connectors, the Engine Coolant Temperature (ECT) sensor one and two connectors, CKP connector, EGR connector, rocker arm oil control connector, rocker arm oil pressure switch connector, oil pressure connector, two A/F sensor connectors, and the two HO2S sensor connectors.
  26.  
  27. Remove the front bank catalytic converter. Remove the rear bank catalytic converter.
    NOTE
    The condenser fan shroud must first be remove to remove the front (bank 2) catalytic converter.



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    Fig. Front (bank 2) catalytic converter and related components-J35Z1 engine



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    Fig. Rear (bank 1) catalytic converter and related components-J35Z1 engine

  28.  
  29. Remove the quick connect fitting cover. Disconnect the fuel feed hose.
  30.  
  31. Remove the two nuts retaining the EVAP canister purge valve joint.
  32.  
  33. Remove the connector bracket from the front cylinder head.
  34.  
  35. Remove the harness clamp bracket from the rear cylinder head.
  36.  
  37. Remove the fuel rails.

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    Fig. Fuel rails and related components-J35Z1 engine



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    Fig. Water passage pipe and related components-J35Z1 engine

  38.  
  39. Remove the water passage pipe. Be sure to use new O-rings and gaskets when installing this component.
  40.  
  41. Remove the front and rear camshaft pulleys and back covers.

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    Fig. Camshaft pulley and cover location-J35Z1 engine



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    Fig. Front valve cover and related components-J35Z1 engine



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    Fig. Rear valve cover and related components-J35Z1 engine



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    Fig. Front cylinder head rocker shafts and related components-J35Z1 engine



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    Fig. Rear cylinder head rocker shafts and related components-J35Z1 engine

  42.  
  43. Remove the valve covers.
  44.  
  45. Remove the cylinder head bolts in the proper sequence.
    WARNING
    To prevent warpage, loosen the bolts in sequence on third turn at a time. Repeat the sequence until all bolts are removed.



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    Fig. Front cylinder head bolt removal sequence-J35Z1 engine



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    Fig. Rear cylinder head bolt removal sequence-J35Z1 engine



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    Fig. Cylinder head and related components-J35Z1 engine

  46.  
  47. Remove the cylinder heads from the engine.
  48.  

To install:

  1. Be sure to clean the cylinder head and engine block surfaces of old gasket material.
  2.  
  3. Be sure to use new O-rings and gaskets, as required.
  4.  
  5. Install the oil control orifices, using new O-rings.
  6.  
  7. Install the dowel pins and new cylinder head gaskets.

    Click image to see an enlarged view

    Fig. Oil control orifice and dowel pin location-J35Z1 engine

  8.  
  9. Clean the timing belt pulleys, timing belt guide plate and upper and lower covers.
  10.  
  11. Set the timing belt drive pulley to TDC, by aligning the TDC mark on the tooth of the timing belt drive pulley with the pointer on the oil pump.

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    Fig. Timing belt drive pulley alignment marks-J35Z1 engine



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    Fig. Front camshaft pulley alignment marks-J35Z1 engine



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    Fig. Rear camshaft pulley alignment marks-J35Z1 engine

  12.  
  13. Set the camshaft pulleys to TDC by aligning the TDC marks on the camshaft pulleys with the pointers on the back covers.
  14.  
  15. Install the cylinder heads on the cylinder block.
  16.  
  17. Measure the diameter of each cylinder head bolt at point -A- and point -B-, see illustration. If either diameter is less than 0.42 in., replace the bolt. Apply clean engine oil to the threads and under the bolt heads of all bolts.

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    Fig. Cylinder head bolt measuring points-J35Z1 engine



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    Fig. Front cylinder head bolt tightening sequence-J35Z1 engine



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    Fig. Rear cylinder head bolt tightening sequence-J35Z1 engine

  18.  
  19. Tighten the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm).
    WARNING
    When using a preset type torque wrench, be sure to tighten slowly and do not over tighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it.

  20.  
  21. After torquing all cylinder head bolts in two steps (90 degrees per step). If you are using a new cylinder head bolt, tighten the bolt an extra ninety degrees.
    WARNING
    Remove the cylinder head bolt if you tighten it beyond the specified angle, and repeat the procedure. Be sure to re-measure the bolt. Do not loosen it back to the specified angle.



    Click image to see an enlarged view

    Fig. Cylinder head bolt additional degree tightening sequence-J35Z1 engine

  22.  
  23. Continue the installation in the reverse order of the removal procedure.
  24.  
  25. Adjust the valves.
  26.  
  27. Be sure to fill the cooling system with the proper grade and type engine coolant.
  28.  
  29. Be sure to check for fuel leaks, Turn the ignition switch ON (II) (do not operate the starter) so the fuel pump runs for about two seconds and pressurizes the fuel line. Repeat this operation three times and check for fuel leakage. Correct, as required.
  30.  
  31. Perform the CKP pattern clear/relearn procedure as follows.
    NOTE
    The Honda Diagnostic Service (HDS) tool should be used to perform this operation. Follow the directions using the HDS tool. If the tool is not available, precede as indicated below.

  32.  
  33. Start the engine. Hold the engine speed at 3000 rpm-s, without a load in either PARK or NEUTRAL until the radiator fan comes on.
  34.  
  35. Test drive the vehicle on a level road. Decelerate with the throttle fully closed from an engine speed of 2500 rpm-s down to 1000 rpm-s with the transmission in the 2 position.
  36.  
  37. Test drive the vehicle on a level road. Decelerate with the throttle fully closed from an engine speed of 5000 rpm-s down to 3000 rpm-s with the transmission in the 2 position.
  38.  
  39. Repeat the above steps several times.
  40.  
  41. Turn the ignition switch OFF.
  42.  
  43. Turn the ignition switch to LOCK (O). Turn the ignition switch to ON (II) and wait thirty seconds.
    NOTE
    The PCM idle learn procedure must be performed when the PCM is replaced, the PCM is reset, the PCM is updated and the throttle body is replaced or cleaned.


    NOTE
    Erasing DTC-s with the HDS tool, does not require you to do the relearn procedure.


    NOTE
    The Honda Diagnostic Service (HDS) tool should be used to perform this operation. Follow the directions using the HDS tool.

  44.  
  45. Perform the PCM idle learn procedure as follows. Make sure that all electrical items are OFF.
  46.  
  47. Using the HDS, reset the PCM .
  48.  
  49. Turn the ignition switch ON (II) and wait two seconds.
  50.  
  51. Start the engine. Hold the engine speed at 3000 rpm-s without a load (PARK or NEUTRAL) until the radiator fan comes on or the engine operating temperature reaches 194° F.
  52.  
  53. Let the engine idle for about five minutes, with the throttle fully closed.
    NOTE
    If the radiator fan comes on do not include its running time in the five minutes.

  54.  
  55. Inspect the idle speed. Inspect the ignition timing.
    NOTE
    The power window reset procedure must be performed when disconnecting the battery, removing the No. 1 (20 amp) fuse in the passenger-s under dash fuse/relay box, disconnecting the 18P connector from the power window control unit, removing the window regulator, glass or glass run channel and disconnecting the driver-s door wire harness.

  56.  
  57. Turn the ignition switch OFF.
  58.  
  59. Turn the ignition switch ON (II).
  60.  
  61. Move the driver-s power window all the way down by holding the driver-s power window switch firmly down to the second detent. When the window reaches the bottom, hold the driver-s power window switch in the AUTO DOWN position for two seconds.
  62.  
  63. Move the driver-s power window all the way up without stopping by holding the driver-s power window switch firmly up to the second detent. When the window reaches the top, hold the driver-s power window switch in the AUTO UP position for two seconds.
    NOTE
    If the power window does not work in AUTO, repeat the procedure.

  64.  

 
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