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Radiator and Fan Replacement

WARNING: This page is about a different car, the 2008 Honda Pilot, 2007 Honda Pilot, and 2006 Honda Pilot. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the wires 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 any other wiring or hoses, or interfere with any other parts.
  1. Make sure you have the anti-theft codes for the radio and navigation system, then write down the customer's audio presets.
  2. Disconnect the negative cable from the battery first, then disconnect the positive cable.
  3. Remove the battery.
  4. Remove the harness clamps (A), then remove the battery tray (B).
    Fig 1: Removing Harness Clamps And Battery Tray (B) With Torque Specifications
    G04245033Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove the harness bracket (C).
  6. Remove the three mounting bolts (D), and loosen the mounting bolt (E), then remove the battery base (F).
  7. Remove the bulkhead cover.
  8. Disconnect the A/C compressor clutch connector (A), hood switch connector (B), and fan motor connectors (C).
    Fig 2: Disconnecting A/C Compressor Clutch Connector With Torque Specifications
    G04245034Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Remove the harness clips (D).
  10. Remove the ground cable (E) and harness clamp (F).
  11. Drain the engine coolant (see COOLANT REPLACEMENT  ).
  12. Remove the upper radiator hose.
    Fig 3: Removing Upper Radiator Hose
    G04245035Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Remove the bulkhead bracket.
    Fig 4: Removing Bulkhead Bracket With Torque Specifications
    G04245036Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Remove the two bolts (A) securing the radiator fan shroud, then remove the radiator fan shroud assembly (B) from the battery side.
    Fig 5: Removing Two Bolts Securing Radiator Fan Shroud With Torque Specifications
    G04245037Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Remove the two bolts (C), and loosen the two bolts (D) securing the A/C condenser fan shroud, then remove the A/C condenser fan shroud assembly (E) from the battery side.
  16. Remove the lower radiator hose (A) and automatic transmission fluid (ATF) cooler hoses (B). Plug the ATF cooler hoses and lines.
    Fig 6: Removing Lower Radiator Hose And (ATF) Cooler Hoses With Torque Specifications
    G04245038Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Remove the six bulkhead bracket mounting bolts (A) that secure the raditor upper brackets/cushions (B) and A/C condenser brackets (C), then remove the raditor upper brackets/cushions and A/C condenser brackets.
    Fig 7: Removing Radiator Upper Bracket/Cushions And A/C Condenser Brackets With Torque Specifications
    G04245039Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Pull up the radiator assembly (A), then remove the lower cushions (B).
    Fig 8: Removing Lower Cushions
    G04245040Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Install the radiator and fans in the reverse order of removal.
  20. Apply touch-up paint to the bulkhead bracket mounting bolts.
  21. Check the upper and lower cushions are being installed securely.
  22. Adjust the engine hood latch (see ADJUSTMENT ).
  23. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
  24. Fill the radiator with engine coolant, and bleed air from the system (see step  8 in COOLANT REPLACEMENT ).
  25. Do the power window reset procedure (see RESETTING THE POWER WINDOW CONTROL UNIT ).
  26. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's audio presets.
  27. Set the clock. (an vehicles without navigation).
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