2002 American Honda Motor Co., Inc - All Rights Reserved. AII 24284 (0212) ...
plug, then remove the drain plug from the bottom ... Always use Honda Antifreeze
/Coolant. Using a .... harness through the back of the bumper ribs, then secure it ...
INSTALLATION INSTRUCTIONS
Accessory
Application
ENGINE BLOCK HEATER P/N 08T44-S9A-100
2003 ELEMENT
Publications No.
AII 24284 Issue Date
DEC 2002
PARTS LIST
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.”
Engine block heater
Aluminum washer
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.
Heater harness
Protective cap
NOTICE Radiator coolant will damage paint. Quickly rinse any spilled coolant from painted surfaces.
20 Long wire ties (8 not used)
RADIATOR CAP
TOOLS AND SUPPLIES REQUIRED Phillips screwdriver Ratchet 24 mm Socket Torque wrench Diagonal cutters Coolant (Honda All Season Antifreeze/Coolant Type 2) 8 mm and 10 mm Allen sockets Felt-tip pen (White) Tape measure DRAIN PLUG
NOTE •
Always use Honda Antifreeze/Coolant. Using a nonHonda 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 before you add coolant.
© 2002 American Honda Motor Co., Inc - All Rights Reserved.
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AII 24284 (0212)
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3.
Open the hood and remove the radiator cover (five clips).
5.
CLIP
Remove the drain plug from the rear of the engine block near the oil filter. Coolant remaining in the engine jacket will flow out of the drain plug hole when removed. Retain the drain plug to be used if the engine block heater is removed. DRAIN PLUG (Retain.)
RADIATOR COVER
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FRONT
4.
Remove the radiator mount bracket (two bolts). 2508030K
6.
Install the engine block heater with the aluminum washer into the bolt hole using a 24 mm socket and a torque wrench. Torque the engine block heater to 60 N·m (44 lbf-ft). ENGINE BLOCK HEATER 60 N·m (6 kgf·m, 44 lb-ft) ALUMINUM WASHER
BOLT
RADIATOR MOUNT BRACKET
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RADIATOR
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© 2002 American Honda Motor Co., Inc - All Rights Reserved.
7.
9.
Using a tape measure, measure and mark the heater harness at the measurements shown. FELT-TIP PEN
Route the heater harness alongside the vehicle harness and secure the heater harness to the vehicle harness with three wire ties in the areas shown.
HEATER HARNESS
VEHICLE HARNESS MARK
FRONT
170 mm FELTTIP PEN
WIRE TIE (Attach over the mark made at 450 mm.)
WIRE TIE
450 mm 655 mm 2011031K
MARK
8.
MARK
Plug the connector of the heater harness into the engine block heater and route the heater harness over the engine. Secure the heater harness to the vehicle harness with one wire tie in the area shown. HEATER HARNESS HEATER HARNESS
WIRE TIE
ENGINE MOUNT BOLT HEATER VEHICLE HARNESS GROUND HARNESS
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10. Route the heater harness to the back of the right headlight along the vehicle harness, then secure the harnesses with two wire ties in the areas shown.
FRONT WIRE TIE VEHICLE HARNESS ENGINE BLOCK HEATER
WIRE TIE
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MARK WIRE TIE HEATER (Attach over the mark HARNESS BULKHEAD made at 655 mm.) UPPER FRAME
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11. Route the heater harness to the side of the right headlight through the back of the bulkhead upper frame, then hang it down toward the front. Secure the heater harness to the hole in the bulkhead upper frame with two wire ties in the areas shown. © 2002 American Honda Motor Co., Inc - All Rights Reserved.
AII 24284 (0212)
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12. Further secure the heater harness to the holes in the right bulkhead side stay with two wire ties in the areas shown. If the vehicle you are working on is equipped with A/C, check that the heater harness is not interfering with the A/C pipes.
13. If you are also installing fog lights, secure the heater harness to the fog light harness with two wire ties as shown. If the vehicle you are working on is equipped with A/C, check that the heater harness is not interfering with the A/C pipes.
WIRE TIE
WIRE TIE
HEATER HARNESS
HEATER HARNESS
FOG LIGHT HARNESS
RIGHT BULKHEAD SIDE STAY
HEATER HARNESS
HEATER HARNESS
WIRE TIE WIRE TIE
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HEATER HARNESS
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FOG LIGHT HARNESS
HEATER HARNESS
© 2002 American Honda Motor Co., Inc - All Rights Reserved.
14. Route the heater harness out through the front bumper grille. Continue routing the heater harness through the back of the bumper ribs, then secure it to the ribs with two wire ties as shown.
HEATER HARNESS
WIRE TIE (Attach over the mark made at 170 mm.) MARK
WIRE TIE
BUMPER RIB
FRONT BUMPER
HEATER HARNESS CONNECTOR
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PROTECTIVE CAP
15. Attach the protective cap to the bumper rib, then plug the heater harness connector into the cap. 16. Reinstall the radiator drain plug, the radiator mount bracket, and the radiator cover. 17. Fill the system with the recommended coolant. Follow the instructions described in the service manual. 18. Check the coolant reservoir for the correct level and signs of leakage. Repair as necessary. 19. Check that the heater harness is routed properly and all connectors are plugged in. 20. Put the drain plug (removed in step 5) in the glove box.
© 2002 American Honda Motor Co., Inc - All Rights Reserved.
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