installation - bernardi parts · 2010. 3. 6. · engine block heater p/n 08t44-sna-101 aii 40257...
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© 2008 American Honda Motor Co., Inc. - All Rights Reserved. AII 40257 (0808) 1 of 13
INSTALLATIONINSTRUCTIONS
Accessory Application Publications No.
Issue Date
AUG 2008
08T44-SHJ-1010-91
2009 ODYSSEYENGINE BLOCK HEATER
P/N 08T44-SNA-101
AII 40257
PARTS LIST
Aluminum washer
Heater harness
Protective cap
12 Black wire ties
Engine block heater
7 Wire tie with clips(Some may not be used.)
5 White wire ties(Some may not be used.)
TOOLS AND SUPPLIES REQUIREDPhillips screwdriverRatchetExtension (6 inch)14, 19, and 24 mm SocketsTorque wrenchDiagonal cuttersCoolant (Honda Antifreeze/Coolant only)White markerTape measure
NOTE
• Always use Honda Antifreeze/Coolant. Using anon-Honda coolant can result in corrosion, causingthe cooling system to malfunction or fail.
• To avoid burning out the element, do not operatethe engine block heater before it is installed in thevehicle and the coolant has been added.
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2 of 13 AII 40257 (0808) © 2008 American Honda Motor Co., Inc. - All Rights Reserved.
7424030Y
7426041Y
8 CLIPS
RADIATOR COVER
CAP
RESERVOIR TANKRADIATOR
FRONT
3. Remove the radiator cover (eight clips).
4. Take the cap off of the reservoir tank.
7426010Y
RADIATOR CAP
DRAIN PLUGFRONT
INSTALLATION
Customer Information: The information in thisinstallation instruction is intended for use only byskilled technicians who have the proper tools,equipment, and training to correctly and safely addequipment to your vehicle. These proceduresshould not be attempted by “do-it-yourselfers.”
If the vehicle you are working on has a VTECengine, continue with step 1. If equipped with aVCM2 engine, go to step 29.
With VTEC Engine:
1. Allow the engine and all cooling systemcomponents to cool down.
2. Place a clean drain pan under the radiator drainplug, then remove the drain plug from the bottomof the radiator to drain the coolant. Remove theradiator cap to increase the flow.
NOTICERadiator coolant will damage the body paint. Quicklyrinse any spilled coolant from the painted surfaces.
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© 2008 American Honda Motor Co., Inc. - All Rights Reserved. AII 40257 (0808) 3 of 13
7426050Y
7426060Y
FRONT
2 BOLTS
RESERVOIR TANKRESERVOIR TANKBRACKET
FRONT
RESERVOIR TANK
TAB
5. Remove two bolts from the reservoir tank.
6. Remove the reservoir tank and the reservoir tankbracket (one tab).
7. Remove two bolts from the radiator brackets, andremove the radiator brackets.
8. Remove the bolt from the lower oxygen sensorwire bracket, and move the bracket out of the way.
7629010B
BOLT
BOLT
RADIATORBRACKET RADIATOR
BRACKET
7629020B
BOLT
OXYGENSENSOR
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4 of 13 AII 40257 (0808) © 2008 American Honda Motor Co., Inc. - All Rights Reserved.
4525011Y
WHITEMARKER
2 MARKS
HEATERHARNESS
170 mm
340 mm
WHITEMARKER
7426080Y
HEATERHARNESS
LOWER GRILLE
11. Using a white marker and a tape measure, markthe indicated position of the heater harness asshown.
12. Pass the heater harness through the indicatedhole on the lower grille as shown.
7426070Y
WASHER
DRAIN BOLT(Retain.)Use a 19 mmsocket.
9. Locate and remove the drain bolt from the front ofthe block using a 19 mm socket. Coolantremaining in the engine jackets will flow out fromthe hole when the drain bolt is removed. (Retainthe drain bolt, in case the engine block heater isremoved.)
4301030Y
ALUMINUMWASHER
ENGINE BLOCK HEATER60 N·m (44 lb-ft)Use a 24 mm socket.
FRONT
10. Install the engine block heater and the aluminumwasher into the hole using a 24 mm socket.Torque the engine block heater to 60 N·m (44 lb-ft).
A
B
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© 2008 American Honda Motor Co., Inc. - All Rights Reserved. AII 40257 (0808) 5 of 13
4301040Y
VEHICLEBRACKET
WHITEWIRE TIE(point A)
HEATERHARNESS
ENGINEBLOCKHEATER
HEATERHARNESSCONNECTOR
7426091Y
7426100Y
7426110Y
FRONT
BUMPER
FRONT
VEHICLE HARNESS
HEATER HARNESS
FRONT
HEATERHARNESS
LEFT HEADLIGHT
HEATER HARNESS
FAN SHROUD
15. Route the heater harness along the fan shroud.13. Route the heater harness towards the leftheadlight.
14. Route the heater harness along the vehicleharness.
16. Plug the connector end of the heater harness intothe engine block heater. Route the heater harnessin the direction shown, and secure it to the vehiclebracket with a white wire tie (point A).
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6 of 13 AII 40257 (0808) © 2008 American Honda Motor Co., Inc. - All Rights Reserved.
7426121Y
7426130Y
HEATERHARNESS
FRONT BUMPER BEAM
2 WIRE TIES(Tie together.)
LEFT HEADLIGHT
HEATER HARNESS
WIRE TIE
HEADLIGHT BRACKET
20. Secure the heater harness to the headlight bracketwith one wire tie.
21. Route the heater harness along the front bumperbeam, and secure the heater harness to the frontbumper beam with four wire ties.
FRONT
4301062Y
VEHICLEHARNESS
3 WIRE TIES
HEATERHARNESS
FRONT
4301051 Y
HEATERHARNESS
2 WIRE TIES
FAN SHROUD
17. Secure the heater harness with one wire tie (pointB).
18. Secure the heater harness with two wire ties.
19. Secure the heater harness to the vehicle harnesswith three wire ties.
WIRE TIE(point B)
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© 2008 American Honda Motor Co., Inc. - All Rights Reserved. AII 40257 (0808) 7 of 13
7426141Y
PROTECTIVE CAP
HEATER HARNESS
LOWERGRILLEPROTECTIVE CAP
7509010X
WIRE TIE
HEATER HARNESS
LOWER GRILLE
PROTECTIVE CAP
22. Attach the protective cap to the lower grille asshown, and plug the heater harness connector intothe protective cap.
24. Reinstall the radiator drain plug.
25. Fill the system with the recommended coolant.Follow the instructions described in the servicemanual to fill and bleed the cooling system.
26. Check the coolant reservoir for correct level andcheck the cooling system for signs of leakage.Repair if necessary.
27. Check that the heater harness is routed properlyand all connectors are plugged in.
28. Put the drain bolt (removed in step 9) in the glovebox.
NOTE: When the battery is disconnected, the driver’swindow AUTO function is disabled.
• Start the engine. Push down on the driver’swindow switch until the window is fully open.
• Pull up on the driver’s window switch to close thewindow completely, then hold the switch for1 second or more.
• Lower and raise the driver’s window to checkoperation of the driver’s window AUTO function.
23. Secure the heater harness to the lower grille with awire tie.
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8 of 13 AII 40257 (0808) © 2008 American Honda Motor Co., Inc. - All Rights Reserved.
7426040Y
CAP
RESERVOIR TANKRADIATOR
7426050Y
FRONT
2 BOLTSRESERVOIR TANK
32. Take the cap off of the reservoir tank.
33. Remove two bolts from the reservoir tank.
7426010Y
DRAIN PLUGFRONT
7424030Y
8 CLIPS
RADIATOR CAP
RADIATOR COVER
31. Remove the radiator cover (eight clips).
With VCM2 Engine:
29. Allow the engine and all cooling systemcomponents to cool down.
30. Place a clean drain pan under the radiator drainplug, then remove the drain plug from the bottomof the radiator to drain the coolant. Remove theradiator cap to increase the flow.
NOTICERadiator coolant will damage the body paint. Quicklyrinse any spilled coolant from the painted surfaces.
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© 2008 American Honda Motor Co., Inc. - All Rights Reserved. AII 40257 (0808) 9 of 13
7426150Y
7426060Y
RESERVOIR TANKRESERVOIR TANKBRACKET
FRONT
WASHER
DRAIN BOLT(Retain.)Use a 19 mmsocket.
TAB
34. Remove the reservoir tank and the reservoir tankbracket (one tab).
37. Locate and remove the drain bolt from the front ofthe block using a 19 mm socket. Coolantremaining in the engine jackets will flow out fromthe hole when the drain bolt is removed. (Retainthe drain bolt, in case the engine block heater isremoved.)
7629010B
BOLT
BOLT
RADIATORBRACKET RADIATOR
BRACKET
35. Remove two bolts from the radiator brackets, andremove the radiator brackets.
36. Remove the bolt from the lower oxygen sensorwire bracket, and move the bracket out of the way.
7629020B
BOLT
OXYGENSENSOR
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10 of 13 AII 40257 (0808) © 2008 American Honda Motor Co., Inc. - All Rights Reserved.
7426091Y
BUMPER
HEATER HARNESS
7426080Y
HEATERHARNESS
LOWER GRILLE
LEFT HEADLIGHT
40. Pass the heater harness through the indicatedhole on the lower grille as shown.
41. Route the heater harness toward the left headlight.
FRONT
7627010B
7427010Y
ALUMINUMWASHER
ENGINE BLOCK HEATER60 N·m (44 lb-ft)Use a 24 mm socket.
FRONT
WIRE TIEWITH CLIP
MARK
HEATERHARNESS
150 mm
300 mm
WHITEMARKER
38. Install the engine block heater and the aluminumwasher into the hole using a 24 mm socket.Torque the engine block heater to 60 N·m (44 lb-ft).
39. Using a tape measure, install one wire tie with clipto the heater harness and mark the indicatedposition using a white marker on the heaterharness as shown.
A
B
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© 2008 American Honda Motor Co., Inc. - All Rights Reserved. AII 40257 (0808) 11 of 13
7427031Y
7427040Y
VEHICLEBRACKET
HEATERHARNESS
ENGINEBLOCKHEATER
HEATERHARNESSCONNECTOR
WIRE TIEWITH CLIP(point A)
FRONT
HEATERHARNESS
FAN SHROUD
3 WIRE TIES
44. Plug the connector end of the heater harness intothe engine block heater. Route the heater harnessin the direction shown, and secure it to the vehiclebracket with a wire tie with clip (point A).
45. Secure the heater harness with one white wire tie(point B), and secure the heater harness with onewhite wire tie.
7426100Y
7427020Y
FRONT
VEHICLE HARNESS
HEATER HARNESS
FRONT
HEATERHARNESS
FAN SHROUD
42. Route the heater harness along the vehicleharness.
43. Route the heater harness along the fan shroud.
46. Secure the heater harness with three wire ties.
WHITEWIRE TIE(point B)
WHITEWIRE TIE
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12 of 13 AII 40257 (0808) © 2008 American Honda Motor Co., Inc. - All Rights Reserved.
7426130Y
7426140Y
HEATERHARNESS
FRONT BUMPER BEAM
2 WIRE TIES(Tie together.)
PROTECTIVE CAP HEATER HARNESSCONNECTOR
LOWERGRILLE
PROTECTIVE CAP
49. Route the heater harness along the front bumperbeam, and secure the heater harness to the frontbumper beam with four wire ties.
50. Attach the protective cap to the lower grille asshown, and plug the heater harness connector intothe protective cap.
7427050Y
7426121Y
FRONT
HEATER HARNESS
VEHICLE HARNESS
HEATER HARNESS
3 WIRE TIES
LEFT HEADLIGHT
WIRE TIE
HEADLIGHT BRACKET
47. Secure the heater harness to the vehicle harnesswith three wire ties.
48. Secure the heater harness to the headlight bracketwith one wire tie.
FRONT
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© 2008 American Honda Motor Co., Inc. - All Rights Reserved. AII 40257 (0808) 13 of 13
7509010X
WIRE TIE
HEATER HARNESS
LOWER GRILLE
PROTECTIVE CAP
51. Secure the heater harness to the lower grille withone wire tie.
52. Reinstall the radiator drain plug.
53. Fill the system with the recommended coolant.Follow the instructions described in the servicemanual to fill and bleed the cooling system.
54. Check the coolant reservoir for correct level andcheck the cooling system for signs of leakage.Repair as necessary.
55. Check that the heater harness is routed properlyand all connectors are plugged in.
56. Put the drain bolt (removed in step 37) in theglove box.
NOTE: When the battery is disconnected, the windowdriver’s window AUTO function is disabled.
• Start the engine. Push down on the driver’s windowswitch until the window is fully open.
• Pull up on the driver’s window switch to close thewindow completely, then hold the switch for1 second or more.
• Lower and raise the driver’s window to checkoperation of the driver’s window AUTO function.
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