Honda Pilot: Engine Removal and Installation

Removal

NOTE:

• Use fender covers to avoid damaging painted surfaces.
• To avoid damaging the wiring and terminals, unplug the wiring connectors carefully while holding the connector portion.
• 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. Hood - Wide Open

1. Open the hood, and secure it with the hood support rod (A) in the wide-open position (B).

2. Engine Cover - Remove

3. Fuel Pressure - Relieve

4. Air Cleaner - Remove

5. 12 Volt Battery - Remove

6. 12 Volt Battery Box - Remove

7. Intake Air Duct - Remove

8. Connector (PCM and Engine Wire Harness) - Disconnect

1. Remove the harness clamp (A).

2. Disconnect the connectors (B).

9. Fuel Feed Hose (High Pressure Fuel Pump Side) - Disconnect

10.EVAP Canister Purge Joint - Move

1. Disconnect the EVAP canister purge hose (A).
2. Move the EVAP canister purge joint.

11.Brake Booster Vacuum Hose - Disconnect

1. Disconnect the brake booster vacuum hose (A).

12.Steering Joint - Disconnect

NOTE: Hold the steering wheel using the steering wheel holder tool.

13.Shift Cable (Transmission Side) - Disconnect (6-Speed A/T)

NOTE: Do not bend the shift cable excessively.

14.Radiator Cap - Remove

15.Vehicle - Lift

1. Raise and support the vehicle.

16.Front Wheel - Remove

17.Engine Coolant - Drain

18.Engine Oil - Drain

19.ATF - Drain

20.Front Inner Fender - Remove

NOTE: Remove the appropriate portion of the front inner fender.

21.Under-Floor TWC - Remove

NOTE: Do not remove the front secondary HO2S.

22.Propeller Shaft - Remove (AWD)

23.Transfer Assembly - Remove (AWD)

24.Connector (Front Suspension Stroke Sensor) - Disconnect (With Auto Leveling System)

1. Remove the nut (A).
2. Disconnect the connector (B).
3. Remove the harness clips (C).

25.Front Stabilizer Link Ball Joint - Disconnect

26.Tie-Rod End Ball Joint - Disconnect

27.Front Lower Arm Ball Joint - Disconnect

28.Front Driveshaft - Remove

29.Vehicle - Lift

1. Lower the vehicle.

30.Harness Holder - Move (6-Speed A/T)

31.Heater Hose - Disconnect

6-Speed A/T

9-Speed A/T

1. Disconnect the heater hoses (A).

32.Radiator - Remove

33.Alternator - Remove

34.Right Front Bulkhead Brace - Remove

35.A/C Compressor - Move

NOTE:

• Do not disconnect the A/C hoses.
• Do not bend the A/C hoses excessively.
• Hang the A/C compressor with a wire tie.

36.Positive Cable - Disconnect

1. Disconnect the positive cables (A).

2. Remove the harness clamp (B).
3. Disconnect the positive cable (C).
4. Remove the connector clamp (D).
5. Disconnect the connector (E).

37.Connector Bracket and Harness Bracket - Move

1. Move the connector bracket (A) from the front cylinder head; use the bracket bolt hole (B) to attach the engine hanger balance bar front arm.

2. Move the harness bracket (C) from the rear cylinder head; use the bracket bolt hole (D) to attach the 2008 V6 attachment arm with the engine hanger balance bar.

38.Cowl Cover - Remove

39.Engine Support Hanger - Install

1. Remove the front damper caps.
2. Install the engine hanger balance bar (A). Attach the front arm (B) to the front cylinder head with a 10 mm (0.39 in) spacer (C) and a 10 x 1.25 mm bolt (D). Remove the rear arm from the engine hanger balance bar, then install the 2008 V6 attachment arm (E). Attach the 2008 V6 attachment arm to the rear cylinder head with a 10 mm (0.39 in) spacer (F) and an 8 x 1.25 mm bolt (G).
3. Install the engine support hanger (H) onto the vehicle as shown, and attach the hook to the slotted hole in the engine hanger balance bar. Tighten the wing nut (I) by hand, and lift and support the engine/transmission.

NOTE:

• Be careful when working around the windshield.
• AAR-T1256 two sets required for stacking additional cross section bars.

40.No. 6 Cylinder Ignition Coil - Remove

41.Front Engine Mount Stop and Front Engine Mount Mounting Bolt - Remove

42.Vehicle - Lift

1. Raise the vehicle.

43.Connector (Front Engine Mount Actuator) - Disconnect

1. Disconnect the connector (A).
2. Remove the harness clip (B).

44.Rear Engine Mount Stop and Rear Engine Mount Mounting Bolt - Remove

45.Connector (Rear Engine Mount Actuator) - Disconnect

1. Disconnect the connector (A).
2. Remove the harness clip (B).

46.Transmission Ground Cable - Disconnect

6-Speed A/T

9-Speed A/T

47.Transmission Mount Mounting Bolt (Transmission Side) - Remove

48.Front Subframe - Support

1. Attach the subframe adapter to the front subframe by looping the belt (A) over the front of the front subframe, then secure the belt with its stop (B), and tighten the wing nut (C).
2. Raise a transmission jack and line up the slots in the subframe adapter arms with the bolt holes on the transmission jack base, then securely attach them with four bolts.

49.Front Subframe - Remove

50.Vehicle - Lift

1. Lower the vehicle.

51.12 Volt Battery Duct - Remove

52.Battery Base - Remove (6-Speed A/T)

1. Remove the harness clips (A) and the battery base.

53.Chain Hoist - Attach

1. Attach a chain hoist (A) to the engine hanger (B) and the transmission hanger (C), then lift the engine/transmission until it is securely supported by the chain hoist.

54.Engine Support Hanger, Engine Hanger Balance Bar, and 2008 V6 Attachment Arm - Remove

55.Upper Half of Side Engine Mount Bracket Mounting Bolt (Engine Side) - Remove

56.Engine - Remove

1. Check that the engine/transmission is completely free of the vacuum hoses, the fuel hoses, the coolant hoses, and the electrical wiring.
2. Slowly lower the engine/transmission about 150 mm (5.91 in). Check once again that all the hoses and the electrical wiring are disconnected and free from the engine/transmission, then lower it all the way and support it.
3. Remove the chain hoist from the engine/transmission.
4. Raise the vehicle, and remove the engine/transmission from under the vehicle.

Installation

1. Engine Mount Bracket - Install

1. Install the engine mount brackets and the accessory brackets, then tighten the bolts to the specified torque.

2. Engine - Install

1. Position the engine/transmission under the vehicle. Be sure that they are properly aligned. Carefully lower the vehicle until the engine/transmission are properly positioned in the engine compartment. Make sure the vehicle is not resting on any part of the engine/transmission. Support the engine/transmission with a chain hoist (A) and carefully raise the engine/transmission into place.

   NOTE: Reinstall the mounting bolts/support nuts in the sequence given in the following steps. Failure to follow this sequence may cause excessive noise and vibration, and reduce engine mount life.

3. Upper Half of Side Engine Mount Bracket Mounting Bolt (Engine Side) - Loosely Install

NOTE: Always use new bolts.

4. Engine Support Hanger - Install

1. Install the engine hanger balance bar (A). Attach the front arm (B) to the front cylinder head with a 10 mm (0.39 in) spacer (C) and a 10 x 1.25 mm bolt (D). Remove the rear arm from the engine hanger balance bar, then install the 2008 V6 attachment arm (E). Attach the 2008 V6 attachment arm to the rear cylinder head with a 10 mm (0.39 in) spacer (F) and an 8 x 1.25 mm bolt (G).
2. Install the engine support hanger (H) onto the vehicle as shown, and attach the hook to the slotted hole in the engine hanger balance bar. Tighten the wing nut (I) by hand, and lift and support the engine/transmission.

NOTE:

• Be careful when working around the windshield.
• AAR-T1256 two sets required for stacking additional cross section bars.

5. Chain Hoist - Remove

6. Battery Base - Install (6-Speed A/T)

1. Install the battery base and the harness clips (A).

7. 12 Volt Battery Duct - Install

8. Vehicle - Lift

1. Raise the vehicle.

9. Front Subframe - Support

1. Attach the subframe adapter to the front subframe by looping the belt (A) over the front of the front subframe, then secure the belt with its stop (B), and tighten the wing nut (C).
2. Raise a transmission jack and line up the slots in the subframe adapter arms with the bolt holes on the transmission jack base, then securely attach them with four bolts.

10.Front Subframe - Install

NOTE: Align the front subframe with the subframe alignment pin.

11.Transmission Mount Mounting Bolt (Transmission Side) - Loosely Install

12.Transmission Ground Cable - Connect

6-Speed A/T

9-Speed A/T

13.Connector (Front Engine Mount Actuator) - Connect

1. Install the harness clip (A).
2. Connect the connector (B).

14.Connector (Rear Engine Mount Actuator) - Connect

1. Install the harness clip (A).
2. Connect the connector (B).

15.Rear Engine Mount and Rear Engine Mount Stop Mounting Bolt - Loosely Install

NOTE: Always use a new bolt and new nuts.

16.Vehicle - Lift

1. Lower the vehicle.

17.Engine Support Hanger, Engine Hanger Balance Bar, and 2008 V6 Attachment Arm - Remove

NOTE: After removing the engine support hanger, install the front damper caps.

18.Cowl Cover - Install

19.Front Engine Mount and Front Engine Mount Stop Mounting Bolt - Loosely Install

NOTE: Always use a new bolt and new nuts.

20.All Engine Mount Mounting Bolt and Nut - Tighten

21.No. 6 Cylinder Ignition Coil - Install

22.Connector Bracket and Harness Bracket - Install

1. Install the connector bracket (A) to the front cylinder head.

2. Install the harness bracket (B) to the rear cylinder head.

23.Positive Cable - Connect

1. Connect the positive cables (A).

2. Install the harness clamp (B).
3. Connect the positive cable (C).
4. Connect the connector (D).
5. Install the connector clamp (E).

24.A/C Compressor - Install

25.Right Front Bulkhead Brace - Install

26.Alternator - Install

27.Radiator - Install

28.Radiator Fan Shroud Assembly and A/C Condenser Fan Shroud Assembly - Install

29.Heater Hose - Connect

6-Speed A/T

9-Speed A/T

1. Connect the heater hoses (A).

30.Harness Holder - Install (6-Speed A/T)

31.Vehicle - Lift

1. Raise the vehicle.

32.Front Driveshaft - Install

33.Front Lower Arm Ball Joint - Connect

34.Tie-Rod End Ball Joint - Connect

35.Front Stabilizer Link Ball Joint - Connect

36.Connector (Front Suspension Stroke Sensor) - Connect (With Auto Leveling System)

1. Install the nut.
2. Connect the connector (A).
3. Install the harness clips (B).

37.Transfer Assembly - Install (AWD)

38.Propeller Shaft - Install (AWD)

39.Under-Floor TWC - Install

40.Engine Undercover - Install

41.Front Inner Fender - Install

42.Splash Shield - Install

43.Front Wheel - Install

44.Vehicle - Lift

1. Lower the vehicle.

45.Steering Joint - Connect

46.Shift Cable (Transmission Side) - Connect (6-Speed A/T)

47.Brake Booster Vacuum Hose - Connect

1. Connect the brake booster vacuum hose (A).

48.EVAP Canister Purge Joint - Install

1. Install the EVAP canister purge joint.
2. Connect the EVAP canister purge hose (A).

49.Fuel Feed Hose (High Pressure Fuel Pump Side) - Connect

50.Connector (PCM and Engine Wire Harness) - Connect

1. Connect the connectors (A).
2. Install the harness clamp (B).

51.Intake Air Duct - Install

52.12 Volt Battery Box - Install

53.12 Volt Battery - Install

54.Engine Oil - Refill

55.ATF - Refill

56.Engine Coolant - Refill/Air Bleed

57.Fuel Leak - Check

58.Air Cleaner and Air Intake Tube - Install

59.Transmission Gear - Check

1. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.

60.Fluid Leak - Check

61.PCM - Reset

62.CKP Pattern - Clear/Learn

63.Idle Speed - Inspect

64.Ignition Timing - Inspect

65.Front Bulkhead Cover - Install

66.Engine Cover - Install

67.Hood Support Strut Normal Position - Return

68.Wheel Alignment - Check

69.Steering Angle Sensor Neutral Position - Clear

70.Headlight Initial Position - Learn (With Auto Leveling System)

Special Tool Required

• Engine Support Hanger, A and Reds AAR-T1256*

• Engine Hanger Balance Bar VSB02C000019*

• 2008 V6 Attachment Arm SIL02C000033*

• Subframe Adapter VSB02C000016*

*: Available through the Honda Tool and Equipment Program 888-424-6857.