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Water Passage 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.
  1. Drain the engine coolant (see COOLANT REPLACEMENT  ).
  2. Remove the intake manifold (see REMOVAL ).
  3. Remove the upper radiator hose (A) and lower radiator hose (B).
    Fig 1: Removing Upper & Lower Radiator Hose
    G04245024Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Remove the water bypass hose (A) and ground cable (B).
    Fig 2: Removing Water Bypass Hose & Ground Cable
    G04245025Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove the harness holder mounting bolt (C), then remove the harness holder (D) from the bracket.
  6. Remove the heater hoses.
    Fig 3: Removing Heater Hoses
    G04245026Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Remove the engine wire harness connectors from the water passage.
    • Engine coolant temperature (ECT) sensor 1 connector
    • Engine coolant temperature (ECT) sensor 2 connector
    • Exhaust gas recirculation (EGR) valve connector
  8. Remove the water passage (A) and connecting pipe (B).
    Fig 4: Removing Water Passage & Connecting Pipe
    G04245027Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Remove the EGR valve (A), ECT sensor 1 (B), ECT sensor 2 (C), thermostat cover (D), and thermostat (E).
    Fig 5: Removing EGR Valve, ECT Sensor 1, ECT Sensor 2, Thermostat Cover And Thermostat With Torque Specifications
    G04245028Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Install the new rubber seal (F) onto the thermostat, then install the thermostat with pin (G) up, and install the thermostat cover.
  11. Install the ECT sensor 1 and ECT sensor 2, using the new O-rings (H).
  12. Install the EGR valve, using a new gasket (I).
  13. Install the connecting pipe (A) and water passage (B), using the new O-rings (C) and new gaskets (D).
    Fig 6: Installing Connecting Pipe And Water Passage With Torque Specifications
    G04245029Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Install the heater hoses.
    Fig 7: Installing Heater Hoses
    G04245030Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Install harness holder (A) to the bracket, then tighten the mounting bolt (B).
    Fig 8: Tightening Mounting Bolt With Torque Specifications
    G04245031Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Install the water bypass hose (C) and ground cable (D).
  17. Install the upper radiator hose (A) and lower radiator hose (B).
    Fig 9: Installing Upper & Lower Radiator Hose
    G04245032Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Install the intake manifold (see INSTALLATION ).
  19. After installation, check that all tubes, hoses and connectors are installed correctly.
  20. Refill the radiator with engine coolant, then bleed air from the cooling system (see step  8 in COOLANT REPLACEMENT ).
  21. Clean up any spilled engine coolant.
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