INSTALLATION INSTRUCTIONS

Transcription

1 INSTALLATION INSTRUCTIONS Accessory Application Publications No. AII ENGINE BLOCK P/N 08T44-SNA ODYSSEY Issue Date JUNE 2009 PARTS LIST Engine block heater Aluminum washer NOTE Always use Honda Antifreeze/Coolant. Using a non-honda coolant can result in corrosion, causing the cooling system to malfunction or fail. To avoid burning out the element, do not operate the engine block heater before it is installed in the vehicle and the coolant has been added. Heater harness Protective cap 12 Black wire ties 7 Wire tie with clips (Some may not be used.) 5 White wire ties (Some may not be used.) TOOLS AND SUPPLIES REQUIRED Phillips screwdriver Ratchet Extension (6 inch) 14, 19, and 24 mm Sockets Torque wrench Diagonal cutters Coolant (Honda Antifreeze/Coolant only) White marker Tape measure 2009 American Honda Motor Co., Inc. - All Rights Reserved AII (0906) 08T44-SHJ of 13

2 INSTALLATION Customer Information: The information in this installation instruction is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your vehicle. These procedures should not be attempted by do-it-yourselfers. 3. Remove the radiator cover (eight clips). 8 CLIPS If the vehicle you are working on has a VTEC engine, continue with step 1. If equipped with a VCM2 engine, go to step 29. With VTEC Engine: 1. Allow the engine and all cooling system components to cool down. 2. Place a clean drain pan under the radiator drain plug, then remove the drain plug from the bottom of the radiator to drain the coolant. Remove the radiator cap to increase the flow. NOTICE Radiator coolant will damage the body paint. Quickly rinse any spilled coolant from the painted surfaces. RADIATOR COVER 4. Take the cap off of the reservoir tank Y RADIATOR CAP CAP DRAIN PLUG RADIATOR Y Y 2 of 13 AII (0906) 2009 American Honda Motor Co., Inc. - All Rights Reserved.

3 5. Remove two bolts from the reservoir tank. 7. Remove two bolts from the radiator brackets, and remove the radiator brackets. BOLT 2 BOLTS Y RADIATOR BOLT RADIATOR B 6. Remove the reservoir tank and the reservoir tank bracket (one tab). 8. Remove the bolt from the lower oxygen sensor wire bracket, and move the bracket out of the way. BOLT OXYGEN SENSOR TAB Y B 2009 American Honda Motor Co., Inc. - All Rights Reserved. AII (0906) 3 of 13

4 9. Locate and remove the drain bolt from the front of the block using a 19 mm socket. Coolant remaining in the engine jackets will flow out from the hole when the drain bolt is removed. (Retain the drain bolt, in case the engine block heater is removed.) 11. Using a white marker and a tape measure, mark the indicated position of the heater harness as shown. WHITE MARKER 2 MARKS WHITE MARKER WASHER 170 mm A B 340 mm DRAIN BOLT (Retain.) Use a 19 mm socket. 12. Pass the heater harness through the indicated hole on the lower grille as shown Y Y 10. Install the engine block heater and the aluminum washer into the hole using a 24 mm socket. Torque the engine block heater to 60 N m (44 lb-ft). LOWER GRILLE Y ALUMINUM WASHER ENGINE BLOCK 60 N m (44 lb-ft) Use a 24 mm socket Y 4 of 13 AII (0906) 2009 American Honda Motor Co., Inc. - All Rights Reserved.

5 13. Route the heater harness towards the left headlight. 15. Route the heater harness along the fan shroud. LEFT HEADLIGHT FAN SHROUD BUMPER Y 14. Route the heater harness along the vehicle harness Y 16. Plug the connector end of the heater harness into the engine block heater. Route the heater harness in the direction shown, and secure it to the vehicle bracket with a white wire tie (point A). VEHICLE VEHICLE WHITE (point A) ENGINE BLOCK Y CONNECTOR Y 2009 American Honda Motor Co., Inc. - All Rights Reserved. AII (0906) 5 of 13

6 17. Secure the heater harness with one wire tie (point B). (point B) 2 S 20. Secure the heater harness to the headlight bracket with one wire tie. LEFT HEADLIGHT FAN SHROUD HEADLIGHT Y Y 18. Secure the heater harness with two wire ties. 19. Secure the heater harness to the vehicle harness with three wire ties. 21. Route the heater harness along the front bumper beam, and secure the heater harness to the front bumper beam with four wire ties. VEHICLE 3 S 2 S (Tie together.) Y BUMPER BEAM Y 6 of 13 AII (0906) 2009 American Honda Motor Co., Inc. - All Rights Reserved.

7 22. Attach the protective cap to the lower grille as shown, and plug the heater harness connector into the protective cap. PROTECTIVE CAP 24. Reinstall the radiator drain plug. 25. Fill the system with the recommended coolant. Follow the instructions described in the service manual to fill and bleed the cooling system. 26. Check the coolant reservoir for correct level and check the cooling system for signs of leakage. Repair if necessary. 27. Check that the heater harness is routed properly and all connectors are plugged in. 28. Put the drain bolt (removed in step 9) in the glove box. NOTE: When the battery is disconnected, the driver s window AUTO function is disabled. Start the engine. Push down on the driver s window switch until the window is fully open. Pull up on the driver s window switch to close the window completely, then hold the switch for 1 second or more. Lower and raise the driver s window to check operation of the driver s window AUTO function. PROTECTIVE CAP LOWER GRILLE Y 23. Secure the heater harness to the lower grille with a wire tie. LOWER GRILLE PROTECTIVE CAP X 2009 American Honda Motor Co., Inc. - All Rights Reserved. AII (0906) 7 of 13

8 With VCM2 Engine: 29. Allow the engine and all cooling system components to cool down. 30. Place a clean drain pan under the radiator drain plug, then remove the drain plug from the bottom of the radiator to drain the coolant. Remove the radiator cap to increase the flow. NOTICE Radiator coolant will damage the body paint. Quickly rinse any spilled coolant from the painted surfaces. 32. Take the cap off of the reservoir tank. CAP RADIATOR CAP RADIATOR Y 33. Remove two bolts from the reservoir tank. DRAIN PLUG 31. Remove the radiator cover (eight clips) Y 8 CLIPS 2 BOLTS Y RADIATOR COVER Y 8 of 13 AII (0906) 2009 American Honda Motor Co., Inc. - All Rights Reserved.

9 34. Remove the reservoir tank and the reservoir tank bracket (one tab). 36. Remove the bolt from the lower oxygen sensor wire bracket, and move the bracket out of the way. BOLT OXYGEN SENSOR TAB Y 35. Remove two bolts from the radiator brackets, and remove the radiator brackets. BOLT B 37. Locate and remove the drain bolt from the front of the block using a 19 mm socket. Coolant remaining in the engine jackets will flow out from the hole when the drain bolt is removed. (Retain the drain bolt, in case the engine block heater is removed.) WASHER RADIATOR BOLT RADIATOR B DRAIN BOLT (Retain.) Use a 19 mm socket Y 2009 American Honda Motor Co., Inc. - All Rights Reserved. AII (0906) 9 of 13

10 38. Install the engine block heater and the aluminum washer into the hole using a 24 mm socket. Torque the engine block heater to 60 N m (44 lb-ft). 40. Pass the heater harness through the indicated hole on the lower grille as shown. ALUMINUM WASHER ENGINE BLOCK 60 N m (44 lb-ft) Use a 24 mm socket Y LOWER GRILLE Y 39. Using a tape measure, install one wire tie with clip to the heater harness and mark the indicated position using a white marker on the heater harness as shown. 41. Route the heater harness toward the left headlight. WITH CLIP MARK WHITE MARKER LEFT HEADLIGHT 150 mm A 300 mm B BUMPER B Y 10 of 13 AII (0906) 2009 American Honda Motor Co., Inc. - All Rights Reserved.

11 42. Route the heater harness along the vehicle harness. VEHICLE 44. Plug the connector end of the heater harness into the engine block heater. Route the heater harness in the direction shown, and secure it to the vehicle bracket with a wire tie with clip (point A). VEHICLE WITH CLIP (point A) 43. Route the heater harness along the fan shroud Y ENGINE BLOCK CONNECTOR Y 45. Secure the heater harness with one white wire tie (point B), and secure the heater harness with one white wire tie. 3 S WHITE (point B) FAN SHROUD Y FAN SHROUD WHITE Y 46. Secure the heater harness with three wire ties American Honda Motor Co., Inc. - All Rights Reserved. AII (0906) 11 of 13

12 47. Secure the heater harness to the vehicle harness with three wire ties. 49. Route the heater harness along the front bumper beam, and secure the heater harness to the front bumper beam with four wire ties. VEHICLE 3 S 2 S (Tie together.) Y 48. Secure the heater harness to the headlight bracket with one wire tie. LEFT HEADLIGHT BUMPER BEAM Y 50. Attach the protective cap to the lower grille as shown, and plug the heater harness connector into the protective cap. PROTECTIVE CAP CONNECTOR LOWER GRILLE HEADLIGHT Y PROTECTIVE CAP Y 12 of 13 AII (0906) 2009 American Honda Motor Co., Inc. - All Rights Reserved.

13 51. Secure the heater harness to the lower grille with one wire tie. LOWER GRILLE PROTECTIVE CAP X 52. Reinstall the radiator drain plug. 53. Fill the system with the recommended coolant. Follow the instructions described in the service manual to fill and bleed the cooling system. 54. Check the coolant reservoir for correct level and check the cooling system for signs of leakage. Repair as necessary. 55. Check that the heater harness is routed properly and all connectors are plugged in. 56. Put the drain bolt (removed in step 37) in the glove box. NOTE: When the battery is disconnected, the window driver s window AUTO function is disabled. Start the engine. Push down on the driver s window switch until the window is fully open. Pull up on the driver s window switch to close the window completely, then hold the switch for 1 second or more. Lower and raise the driver s window to check operation of the driver s window AUTO function American Honda Motor Co., Inc. - All Rights Reserved. AII (0906) 13 of 13