Accessory Application Publications No. AII 24284 ENGINE BLOCK HEATER INSTALLATION 2003 ELEMENT P/N 08T44-S9A-100 Issue Date INSTRUCTIONS DEC 2002 PARTS LIST INSTALLATION Customer Information: The information in this Engine block heater 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.” Aluminum washer 1. Allow the engine and all cooling system Heater harness 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 Protective cap radiator cap to increase the flow. 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 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 2508020K vehicle and before you add coolant. © 2002 American Honda Motor Co., Inc - All Rights Reserved. AII 24284 (0212) 08T44-SCV-1000-91 1 of 5 3. Open the hood and remove the radiator cover (five 5. Remove the drain plug from the rear of the engine clips). 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 CLIP the engine block heater is removed. DRAIN PLUG (Retain.) RADIATOR 2328091K COVER 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 2829110K MOUNT BRACKET RADIATOR 2508040K 2 of 5 AII 24284 (0212) © 2002 American Honda Motor Co., Inc - All Rights Reserved. 7. Using a tape measure, measure and mark the 9. Route the heater harness alongside the vehicle heater harness at the measurements shown. harness and secure the heater harness to the vehicle harness with three wire ties in the areas shown. FELT-TIP PEN HEATER VEHICLE HARNESS HARNESS MARK FRONT 170 mm FELT- TIP WIRE TIE PEN (Attach over the WIRE mark 450 mm TIE made at 450 mm.) 655 mm MARK 2011031K ENGINE MOUNT BOLT 8. Plug the connector of the heater harness into the MARK 2508062K engine block heater and route the heater harness HEATER VEHICLE over the engine. Secure the heater harness to the HARNESS GROUND vehicle harness with one wire tie in the area HARNESS shown. 10. Route the heater harness to the back of the right HEATER headlight along the vehicle harness, then secure HARNESS the harnesses with two wire ties in the areas WIRE TIE shown. HEATER HARNESS FRONT WIRE TIE VEHICLE HARNESS ENGINE BLOCK HEATER WIRE TIE 2508072K HEATER MARK WIRE TIE (Attach over the mark 2508051K HARNESS BULKHEAD UPPER FRAME made at 655 mm.) 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) 3 of 5 12. Further secure the heater harness to the holes in 13. If you are also installing fog lights, secure the the right bulkhead side stay with two wire ties in heater harness to the fog light harness with two the areas shown. If the vehicle you are working on wire ties as shown. If the vehicle you are working is equipped with A/C, check that the heater on is equipped with A/C, check that the heater harness is not interfering with the A/C pipes. harness is not interfering with the A/C pipes. WIRE WIRE TIE TIE HEATER HEATER FOG LIGHT HARNESS HARNESS HARNESS RIGHT BULKHEAD SIDE STAY HEATER HARNESS HEATER HARNESS WIRE TIE WIRE TIE 2517041K HEATER HARNESS 2517031K FOG LIGHT HARNESS HEATER HARNESS 4 of 5 AII 24284 (0212) © 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. WIRE TIE HEATER (Attach over the mark HARNESS made at 170 mm.) MARK WIRE TIE BUMPER RIB FRONT BUMPER HEATER HARNESS CONNECTOR 2517062K 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. AII 24284 (0212) 5 of 5.