Water Passage Removal and Installation
Water Passage Removal and Installation
*Available through the Honda Tool and Equipment Program 888-424-6857.
Removal
1. Radiator Cap
1. Wait until the engine is cool, then carefully remove the radiator cap.
2. Vehicle Lift
1. Raise the vehicle on a lift, and make sure it is securely supported.
3. Radiator Coolant - Replacement
1. Loosen the drain plug (A), and drain the coolant.
4. Engine Cover
1. Remove the engine cover.
5. Fuel Filler Cap
1. Remove the fuel fill cap to relieve the pressure in the fuel tank.
6. HDS DLC - Connection
NOTE: For specific operations, refer to the user's manual that came with the Honda Diagnostic System (HDS). Make sure the HDS is loaded with the latest software.
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
7. Fuel Pump Off
1. Turn the ignition switch to ON (II).
2. From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.
NOTE:
* Do not allow the engine to idle above 1,000 rpm or the ECM/PCM will continue to operate the fuel pump.
* Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.
3. Turn the ignition switch to LOCK (0).
8. Battery Terminal - Disconnection
1. Make sure the ignition switch is in LOCK (0).
2. Disconnect and isolate the negative cable and battery sensor (A) from the battery.
NOTE: Always disconnect the negative side first.
3. Disconnect the positive cable (B) from the battery.
9. Fuel Pressure - Relieving
1. Remove the bracket (A).
2. Remove the quick-connect fitting cover (A).
3. Check the fuel quick-connect fitting for dirt, and clean it if needed.
4. Place a rag or shop towel over the quick-connect fitting (A).
5. Disconnect the quick-connect fitting: Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.
NOTE:
* Be careful not to damage the line (D) or other parts.
* Do not use tools.
* If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.
* Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
10. Intake Air Duct
1. Remove the intake air duct.
11. Intake Manifold Assembly
1. Remove the intake manifold bracket.
2. Remove the intake manifold (A).
3. Disconnect the PCV hose (A).
12. Splash Shield
1. Remove the splash shield (A).
13. Drive Belt
1. Move the auto-tensioner (A) using the belt tension release tool in the direction of the arrow to relieve tension from the drive belt, then remove the drive belt.
14. Idler Pulley Base Assembly
1. Remove the idler pulley base.
15. Auto-Tensioner Assembly
1. Remove the auto-tensioner.
16. Bulkhead - Removal
1. Disconnect the connectors (A).
2. Remove the harness clamps (B).
3. Remove the bulkhead (A).
17. A/C Condenser Fan Shroud Assembly
1. Remove the A/C condenser fan shroud assembly (A).
18. Alternator
1. Remove the three bolts securing the alternator.
2. Disconnect the connector and the cable.
3. Remove the alternator.
19. Compressor Assembly - Move
1. Remove the A/C compressor without disconnecting the A/C hoses. Do not bend the A/C hoses excessively.
NOTE: Hang the A/C compressor with a wire tie.
20. Radiator Connecting Pipe
1. Disconnect the heater hose (A) and the water bypass hose (B).
2. Remove the harness clamp (C) and the connecting pipe mounting bolt (D).
3. Remove the harness clamps (A) and the connecting pipe (B).
21. Water Passage Assembly
1. Disconnect the PCV hose (A) and water bypass hose (B).
2. Remove the water passage (C).
22. Thermostat Housing
1. Remove the thermostat housing
23. WATER PUMP ASSEMBLY
1. Remove the water pump.
Installation
1. WATER PUMP ASSEMBLY
1. Install the water pump (A) with a new O-ring (B)
2. Thermostat Housing
1. Install the thermostat housing (A) with a new O-ring (B).
3. Water Passage Assembly
1. Clean and dry the water passage mating surfaces.
2. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the water passage, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
3. Install the water passage (A) with a new O-ring (B).
NOTE:
* Wait at least 30 minutes before filling the engine with coolant.
* Do not run the engine for at least 3 hours after installing the water passage.
4. Connect the PCV hose (C) and the water bypass hose (D).
4. Radiator Connecting Pipe
1. Install the connecting pipe (A) with a new O-ring (B).
2. Install the harness clamps (C).
3. Install the connecting pipe mounting bolt (A) and the harness clamp (B).
4. Connect the heater hose (C) and the water bypass hose (D).
5. Compressor Assembly - Move
1. Install the A/C compressor.
6. Alternator
1. Connect the connector and the cable.
2. Install the alternator.
7. A/C Condenser Fan Shroud Assembly
1. Install the A/C condenser fan shroud assembly (A).
8. Bulkhead - Installation
1. Install the bulkhead (A).
2. Install the harness clamps (A).
3. Connect the connectors (B).
9. Auto-Tensioner Assembly
1. Install the auto-tensioner.
10. Idler Pulley Base Assembly
1. Install the idler pulley base.
11. Drive Belt
1. Install the drive belt.
12. Splash Shield
1. Install the splash shield (A).
13. Intake Manifold Assembly
1. Connect the PCV hose (A).
2. Install the intake manifold (A) with new gaskets (B).
3. Install the intake manifold bracket.
14. Intake Air Duct
1. Install the intake air duct.
15. Engine Cover
1. Install the engine cover.
16. Fuel Filler Cap
1. Install the fuel fill cap.
17. Battery Terminal - Reconnection
NOTE: If the battery performs abnormally, test the battery.
1. Clean the battery terminals.
2. Connect the positive cable (A) to the battery.
NOTE: Always connect the positive side first.
3. Connect the negative cable and battery sensor (B) to the battery.
4. Apply multipurpose grease to the terminals to prevent corrosion.
18. HDS DLC - Connection
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
19. Fuel Pump On
1. From the INSPECTION MENU of the HDS, select Fuel Pump ON.
NOTE: Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.
2. Turn the ignition switch to LOCK (0).
20. Fuel Line Leak Check
1. Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.
21. Intake Manifold After Install - Check
1. After installation, check that all tubes, hoses, and connectors are installed correctly.
22. Radiator Coolant - Replacement
1. Pour Honda Long Life Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck.
NOTE (Except K24Z7 engine):
* Always use Honda Long Life Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail.
* Honda Long Life Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Do not add water.
NOTE (K24Z7 engine):
* Always use Honda Long Life Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail.
* Honda Long Life Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Do not add water.
* If the vehicle is regularly driven in very low temperatures (under -31 °F,-35 °C) a 60 % concentration of coolant should be used. To accomplish this, pour 1.6 L (0.4 US gal) of Honda Extreme Cold Weather Antifreeze/Coolant Type 2 into the radiator first, then add Honda Long Life Antifreeze/Coolant Type 2 until the radiator is full.
23. Maintenance Minder Reset
1. After doing all procedures, select the individual maintenance item you wish to reset with the HDS (See the Maintenance Minder General Information).