Pilot 2006-2008

Engine

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Removal & Installation




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.
  8.  
  9. Secure the hood in the wide open position.

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    Fig. Securing the hood in the wide open position



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    Fig. Engine cover

  10.  
  11. Remove the engine cover.
  12.  
  13. Properly relieve the fuel system pressure.
  14.  
  15. Drain the engine coolant. Properly dispose of used coolant.
  16.  
  17. Drain the power steering fluid reservoir. Be sure to properly dispose of used fluid.
  18.  
  19. Remove the battery.
  20.  
  21. Disconnect the breather pipe and remove the air intake duct.
  22.  
  23. Remove the battery tray assembly.

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    Fig. Battery tray and related components

  24.  
  25. Disconnect the starter electrical connectors.
  26.  
  27. Remove the shift cable. Do not bend or kink the cable.
  28.  
  29. Remove the quick connect fitting cover, disconnect the fuel feed hose.
  30.  
  31. Remove the brake booster vacuum hose, EVAP canister hose, and EVAP canister purge valve joint.
  32.  
  33. Remove the driver-s side console lower panel, and pull up the carpet to expose the steering joint cover.
  34.  
  35. Remove the steering wheel.
  36.  
  37. Remove the steering joint cover. Matchmark the joint and gearbox pinion shaft. Remove the joint bolt and disconnect the joint from the pinion shaft.
  38.  
  39. Remove the coolant reservoir, do not disconnect the hoses.
  40.  
  41. Remove the bolt retaining the washer tank. Remove the PCM cover.
  42.  
  43. Remove the harness clamps, then disconnect the PCM connectors, accelerator pedal position sensor connector and the engine wire harness connectors, on the right side of the engine compartment.
  44.  
  45. Remove the harness clamps and remove the alternator cable.
  46.  
  47. Remove the power steering pump outlet hose from the pump. Remove the hose clamp.
  48.  
  49. Remove the drive belt. Remove the radiator cap.
  50.  
  51. Raise and support the vehicle safely.
  52.  
  53. Remove the front tire and wheel assemblies.
  54.  
  55. Remove the splash shield.

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    Fig. Splash shield removal points

  56.  
  57. Drain the transmission fluid. Be sure to properly dispose of used fluid.
  58.  
  59. Drain the engine oil. Be sure to properly dispose of used engine oil.
  60.  
  61. Remove the front subframe stiffener.

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    Fig. Subframe stiffener and related components

  62.  
  63. Remove the front exhaust pipe.

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    Fig. Exhaust pipe and related components



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    Fig. Matchmark the driveshaft yoke

  64.  
  65. Matchmark and remove the driveshaft.
  66.  
  67. Remove the transfer case.

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    Fig. Transfer case and related components

  68.  
  69. Separate the stabilizer links from the shocks. Separate the tie rod end ball joints from the knuckles. Separate the knuckles from the suspension lower arm ball joints.
  70.  
  71. Remove the halfshafts.
  72.  
  73. Remove the power steering hose. Plug the line.
  74.  
  75. Disconnect the power steering pressure switch connector.
  76.  
  77. Remove the transmission lower front mount nuts and lower rear mount nuts.

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    Fig. Transmission lower front and rear mount locations

  78.  
  79. Disconnect the ACM connector from the rear engine mount. Remove the harness clamp. Remove the bolt securing the power steering line, if equipped with the J35Z1 engine.
  80.  
  81. Remove the rear engine mount bolts.

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    Fig. Rear engine mount bolt location-J35A9 engine



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    Fig. Rear engine mount bolt location-J35Z1 engine

  82.  
  83. Remove the A/C compressor retaining bolts. Remove the compressor. Position it out of the way. Do not disconnect the refrigerant lines. Hang the compressor, as shown in the illustration.

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    Fig. A/C compressor positioning

  84.  
  85. Disconnect the ACM connector from the front engine mount. Remove the harness clamp, if equipped with the J35Z1 engine.
  86.  
  87. Lower the vehicle from the lift.
  88.  
  89. Remove the heater hoses. Plug the hose to prevent coolant leakage. Remove the upper and lower radiator hoses. Remove the ground cable.
  90.  
  91. Remove the transmission fluid hoses. Plug the hoses to prevent fluid leakage.
  92.  
  93. Remove the radiator.

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    Fig. Radiator and related components

  94.  
  95. Remove the connector bracket from the front cylinder head. Use the bracket bolt hole to attach the engine hanger balance bar front arm.

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    Fig. Front cylinder head bracket location



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    Fig. Rear cylinder head bracket location

  96.  
  97. Remove the harness clamp bracket from the rear cylinder head. Use the bracket bolt hole to attach the engine hanger balance bar rear arm.
  98.  
  99. Install the engine hanger balance bar. Install the engine hanger adapters.

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    Fig. Engine removal fixture and related components

  100.  
  101. Remove the front engine mount, if equipped with J35A1 engine.
  102.  
  103. Remove the front engine mount stop and then the front engine mount bolt, if equipped with J35Z1 engine.

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    Fig. Front engine mount bolt location-J35A9 engine



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    Fig. Front engine mount bolt location-J35Z1 engine

  104.  
  105. Make sure that the hoist brackets are properly positioned. Raise and properly support the vehicle at its full height.
  106.  
  107. Matchmark the front subframe.

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    Fig. Front subframe matchmark positions

  108.  
  109. Loosen the four bolts on the subframe adapter. Install the tool on a suitable transmission jack.

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    Fig. Subframe adapter tool



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    Fig. Subframe adapter tool installation

  110.  
  111. Raise the jack to vehicle height. Attach the adapter tool to the front subframe using the subframe stiffener mounting bolts and bolt holes.
  112.  
  113. Remove the bolt retainers from both ends of the subframe.
  114.  
  115. Remove the six bolts securing the front stiffeners and rear stiffeners, and four bolts securing the front subframe. Lower the front subframe.

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    Fig. Front subframe removal

  116.  
  117. Lower the vehicle from the lift. Attach the engine lifting fixture. Be sure that it is properly installed. Slightly lift the engine and remove the engine support hanger and engine hanger adapters.

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    Fig. Engine lifting fixture/chain hoist attachment

  118.  
  119. Remove the mounting bolts from the upper half of the engine side mount bracket.
  120.  
  121. Check that the engine/transmission assembly is completely free of hoses, wires , straps etc.
  122.  
  123. Slowly lower the assembly about six inches. Once again check that the engine/transmission assembly is free of hoses, wires , straps etc.
  124.  
  125. Lower the engine/transmission assembly all the way. Remove the chain hoist from the assembly.
  126.  
  127. Raise the vehicle all the way on the hoist. Remove the engine/transmission assembly from under the vehicle.
  128.  

To install:

  1. Installation is the reverse of the removal procedure.
    WARNING
    Reinstall the mounting bolts/support nuts and brackets in the sequence given, see illustration. Failure to follow this sequence may cause excessive noise and vibration, which will reduce bushing life.



    Click image to see an enlarged view

    Fig. Engine bracket installation sequence

  2.  
  3. Be sure to fill the cooling system with the proper grade and type engine coolant.
  4.  
  5. Be sure to fill the engine oil with the proper grade and type engine oil.
  6.  
  7. Be sure to fill the transmission with the proper grade and type fluid.
  8.  
  9. Be sure to fill the power steering system with the proper grade and type fluid.
  10.  
  11. 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.
  12.  
  13. 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.

  14.  
  15. 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.
  16.  
  17. 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.
  18.  
  19. 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.
  20.  
  21. Repeat the above steps several times.
  22.  
  23. Turn the ignition switch OFF.
  24.  
  25. 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.

  26.  
  27. Perform the PCM idle learn procedure as follows. Make sure that all electrical items are OFF.
  28.  
  29. Using the HDS, reset the PCM .
  30.  
  31. Turn the ignition switch ON (II) and wait two seconds.
  32.  
  33. 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.
  34.  
  35. 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.

  36.  
  37. 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.

  38.  
  39. Turn the ignition switch OFF.
  40.  
  41. Turn the ignition switch ON (II).
  42.  
  43. 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.
  44.  
  45. 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.

  46.  
  47. Be sure to fill the cooling system with the proper grade and type engine coolant.
  48.  
  49. Check and adjust the front end alignment, as required.
  50.  
  51. Inspect the idle speed. Inspect the timing.
  52.  
  53. Move the transmission selector lever thru each gear and verify that the gear position indicator follows the transmission range switch.
  54.  

 
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