A17-009

Service Bulletin
17-009
August 25, 2017
07239 Version 3
Product Update: 2016 Pilot 9-Speed Transmission Warmer
Supersedes 17-009, dated August 4, 2017, to revise the information highlighted in yellow
AFFECTED VEHICLES
Year
Model
2016
Pilot
Trim
All with 9-speed A/T
VIN Range
Check the iN VIN status for eligibility
REVISION SUMMARY
Two hoses were added to PARTS INFORMATION.
BACKGROUND
Some 9-speed transmission warmers were improperly manufactured and allow the engine coolant and ATF to mix. If the
fluids mix, the engine and transmission may be permanently damaged and require replacement.
CUSTOMER NOTIFICATION
Owners of affected vehicles will be sent a notification of this campaign.
Do an iN VIN status inquiry to make sure the vehicle is shown as eligible.
Some vehicles affected by this campaign may be in your new or used vehicle inventory. Repair these vehicles before
they are sold.
SERVICE ADVISOR
Ask the customer if the vehicle overheated, for example, if the MID showed a message Stop Driving Engine
Temperature Too Hot or there was steam from under the hood. Other signs include coolant leaking from the radiator
cap or the coolant reserve tank.
OR
Write down the customer responses on the RO.
NOTE: Any engine replaced without this documentation on the signed RO will be subject to debit.
CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools,
equipment, and training to correctly and safely maintain your vehicle. These procedures should not be attempted by “do-it-yourselfers,” and
you should not assume this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this
information applies, contact an authorized Honda automobile dealer.
© 2017 American Honda Motor Co., Inc. – All Rights Reserved
Page 1 of 44
CORRECTIVE ACTION
Inspect the vehicle and based on your inspection, do one of the following:
• The transmission warmer is outside the affected date. No further action is needed.
• Replace the transmission warmer.
• Replace the transmission, radiator, thermostat, coolant reserve tank, all of the coolant hoses, ECT sensor (1 and 2)
O-rings (engine coolant temperature sensor), and flush the cooling system.
• Replace the short block, cylinder heads, transmission, radiator, thermostat, coolant reserve tank, all of the coolant
hoses, ECT sensor (1 and 2) O-rings (engine coolant temperature sensor), water passage, water connecting pipe,
and flush the heater core.
NOTE: Photos are required every time a transmission is replaced – see page 17. Any transmission replacement
claims that do not include the required photos may be subject to debit.
The flowchart below provides a summary to help navigate the inspection and repair procedure. Make sure you read the
service bulletin steps thoroughly for the detailed repair information.
Start
Vehicle is OK. No
further action
needed.
Good
Check the ATF warmer date.
No Good
Remove the ATF warmer and check
for leaks.
Does ATF warmer leak?
No
REPAIR PROCEDURE A
Replace the ATF warmer.
The repair is complete.
No
REPAIR PROCEDURE
A and B
- Replace transmission,
radiator, and hoses.
- Flush engine.
Yes
Did the engine overheat?
Yes
REPAIR PROCEDURE A and C
- Replace engine, transmission,
radiator, and hoses.
- Flush heater core.
End
Page 2 of 44
WARRANTY CLAIM INFORMATION
Inspection Only (You cannot combine this LON with any others)
Operation
Number
2325A0
Description
Flat Rate
Time
Defect
Code
Symptom
Code
Template
ID
Failed Part
Number
Inspect the transmission warmer
manufacturing date. Use this
information when the ATF
warmer date is outside affected
range and no further action is
needed.
0.2 hr
6ZF00
KG100
A17009A
06201-5EY-A05
Description
Flat Rate
Time
Defect
Code
Symptom
Code
Template
ID
Failed Part
Number
Inspect the vehicle and do
REPAIR PROCEDURE A only.
2.1 hrs
6ZF00
KG100
A17009B
06201-5EY-A05
Inspection and do REPAIR PROCEDURE A Only
Operation
Number
1110A9
Replace: ATF Warmer
Inspection and do REPAIR PROCEDURE A and REPAIR PROCEDURE B
NOTE: Photos must be submitted with any warranty claim where the transmission is replaced – see page 17. Any
transmission replacement claims that do not include the required photos may be subject to debit.
Operation
Number
1140A5
Description
Transmission
Replacement
Number
Flat
Rate
Time
Defect
Code
Symptom
Code
Template
ID
Failed Part
Number
2WD - Inspect the
vehicle and start at
REPAIR
PROCEDURE A and
also do REPAIR
PROCEDURE B.
06200-5EY-A08RM
10.5 hrs
6ZF00
KG100
A17009C
06201-5EY-A05
06200-5EY-A08RM
10.5 hrs
6ZF00
KG100
A17009D
06201-5EY-A05
- Replace:
transmission,
radiator, and hoses
- Flush engine
- Includes photos,
updating PCM/TCM,
idle learn and
alignment
1140A5
2WD - Inspect the
vehicle and start at
REPAIR
PROCEDURE A and
also do REPAIR
PROCEDURE B.
- Replace:
transmission,
radiator, and hoses
- Flush engine
- Includes photos,
updating PCM/TCM,
idle learn and
alignment
A
Add if the vehicle has
an accessory
external transmission
cooler.
0.9 hr
Page 3 of 44
1140A5
AWD - Inspect the
vehicle and start at
REPAIR
PROCEDURE A and
also do REPAIR
PROCEDURE B.
06200-5EZ-A09RM
10.9 hrs
6ZF00
KG100
A17009E
06201-5EY-A05
06200-5EZ-A09RM
10.9 hrs
6ZF00
KG100
A17009F
06201-5EY-A05
- Replace:
transmission,
radiator, and hoses
- Flush engine
- Includes photos,
updating PCM/TCM,
idle learn and
alignment
1140A5
AWD - Inspect the
vehicle and start at
REPAIR
PROCEDURE A and
also do REPAIR
PROCEDURE B.
- Replace:
transmission,
radiator, and hoses
- Flush engine
- Includes photos,
updating PCM/TCM,
idle learn and
alignment
A
Add if the vehicle has
an accessory
external transmission
cooler.
0.9 hr
Page 4 of 44
Inspection and do REPAIR PROCEDURE A and REPAIR PROCEDURE C
NOTE: Photos must be submitted with any warranty claim where the transmission is replaced – see page 17. Any
transmission replacement claims that do not include the required photos may be subject to debit.
Operation
Number
1010A0
Description
Transmission
Replacement
Number
Flat
Rate
Time
Defect
Code
Symptom
Code
Template
ID
Failed Part
Number
2WD - Inspect the
vehicle and start at
REPAIR
PROCEDURE A
and do REPAIR
PROCEDURE C.
06200-5EY-A08RM
13.1 hrs
6ZF00
KG100
A17009G
06201-5EY-A05
06200-5EY-A08RM
13.1 hrs
6ZF00
KG100
A17009H
06201-5EY-A05
- Replace: engine,
transmission,
radiator, and hoses
- Flush heater core
- Includes photos,
updating
PCM/TCM, idle
learn and alignment
1010A0
2WD - Inspect the
vehicle and start at
REPAIR
PROCEDURE A
and do REPAIR
PROCEDURE C.
- Replace: engine,
transmission,
radiator, and hoses
- Flush heater core
- Includes photos,
updating
PCM/TCM, idle
learn and alignment
A
Add if the vehicle
has an accessory
external
transmission
cooler.
0.9 hr
Page 5 of 44
1010A0
AWD - Inspect the
vehicle and start at
REPAIR
PROCEDURE A
and do REPAIR
PROCEDURE C Replace: engine,
transmission,
radiator, and hoses
06200-5EZ-A09RM
13.5 hrs
6ZF00
KG100
A17009I
06201-5EY-A05
06200-5EZ-A09RM
13.5 hrs
6ZF00
KG100
A17009J
06201-5EY-A05
- Flush heater core
- Includes photos,
updating
PCM/TCM, idle
learn and alignment
1010A0
AWD - Inspect the
vehicle and start at
REPAIR
PROCEDURE A
and do REPAIR
PROCEDURE C Replace: engine,
transmission,
radiator, and hoses
- Flush heater core
- Includes photos,
updating
PCM/TCM, idle
learn and alignment
A
Add if the vehicle
has an accessory
external
transmission
cooler.
0.9 hr
Page 6 of 44
PARTS INFORMATION - REPAIR PROCEDURE A
Part Name
Part Number
Quantity
ATF Warmer Kit (Includes O-rings)
06224-5J4-305
1
Fitting (used only with accessory cooler)
25910-5NC-003
2
Part Name
Part Number
Quantity
ATF Type 3.1
08200-9017
1
OL999-9011
1
REQUIRED MATERIALS – REPAIR PROCEDURE A
NOTE: 1 quart will fill 5 vehicles unless the vehicle has an
accessory ATF cooler.
Honda Genuine Antifreeze/Coolant Type 2
NOTE: 1 gallon will fill 10 vehicles.
Page 7 of 44
PARTS INFORMATION – REPAIR PROCEDURE B
Part Name
Part Number
Quantity
1
Transmission
2WD (includes ATF warmer)
AWD (includes ATF warmer)
06200-5EZ-A09RM
Flange Bolt (12 x 70 mm)
90051-PE0-000
1
Flange Bolt (12 x 120 mm)
95701-12120-08
1
Flange Bolt (10 x 60 mm)
90168-TA1-A00
2
Flange Nut (12 mm)
90371-SAA-010
4
Flange Bolt (10 x 35 mm)
90163-SDA-A01
2
Pre-Chamber Gasket
18393-SDB-A00
1
Exhaust Pipe Gasket (ISHINO)
18212-SA7-003
2
Self-Lock Nut (10 mm)
90212-SA5-003
9
Bolt (12 point 8 x 21 mm) (AWD Only)
90113-S10-000
8
Flange Bolt (10 x 29 mm) (AWD Only)
90382-SH9-003
2
Shaft Ring Seal Kit (AWD) (AWD Only)
06235-5L9-000
1
Flange Nut (12 mm)
90362-SZA-A00
4
Split Pin (3.0 x 22 mm)
94201-30220
2
Castle Nut (14 mm)
90365-STX-A00
2
Flange Bolt (12 x 30 mm)
90161-SHJ-A00
4
Flange Bolt (14 x 140 mm)
90165-TZ5-A10
2
Flange Bolt (14 x 125 mm)
90165-TK8-A00
2
Snap Ring (32 x 2.2 mm)
44319-STX-A01
1
Set Ring (32 x 2.2 mm)
44319-STX-A60
1
Flange Bolt (10 x 30 mm)
90163-SDB-A00
3
Steering Joint Yoke Bolt
90135-TG7-A50
1
Radiator (DENSO)
19010-5J6-A01
1
Warmer Hose B (ATF)
19433-5J2-A00
1
Water Hose A
19521-5J6-A50
1
Water Hose B
19522-5J6-A00
1
Water Hose C
19523-5J6-A10
1
Warmer Hose A (ATF)
19432-5J2-A50
1
Water Hose (Upper)
19501-5J6-A10
1
Water Hose A (Lower)
19502-5J6-A50
1
Water Hose (Lower) (B)
19504-5J2-A50
1
Reserve Tank Tube A
19103-5J6-A00
1
Reserve Tank Tube B
19104-5J6-A00
1
Reserve Tank
19101-5J6-A00
1
Thermostat Cover Assembly
19315-RLV-A51
1
06200-5EY-A08RM
Page 8 of 44
O-Ring (Denso)
91307-RTA-005
2
Reserve Tank Cap
19102-5J6-A00
1
Reserve Tank Joint
19106-RSA-G00
1
Cooler Kit (ATF) (order only if vehicle is equipped with
the accessory tow package)
06255-5EZ-316
1
Inlet Water Hose
79721-TZ5-A10
1
Outlet Water Hose
79725-TZ5-A11
1
REQUIRED MATERIALS – REPAIR PROCEDURE B
Part Name
Part Number
Quantity
ATF Type 3.1
08200-9017
1
OL999-9011
12
NOTE: 1 quart will fill 5 vehicles unless the vehicle has an
accessory ATF cooler.
Honda Genuine Antifreeze/Coolant Type 2
Page 9 of 44
PARTS INFORMATION – REPAIR PROCEDURE C
Part Name
Part Number
Quantity
Transmission
2WD (includes ATF warmer)
AWD (includes ATF warmer)
06200-5EY-A08RM
06200-5EZ-A09RM
Cylinder Block Assembly
10002-5J6-A10
1
Cylinder Head Assembly (Front)
10004-RLV-A00
1
Cylinder Head Assembly (Rear)
10005-RLV-A00
1
Flange Bolt (12 x 70 mm)
90051-PE0-000
1
Flange Bolt (12 x 120 mm)
95701-12120-08
1
Flange Bolt (10 x 60 mm)
90168-TA1-A00
2
Flange Nut (12 mm)
90371-SAA-010
4
Flange Bolt (10 x 35 mm)
90163-SDA-A01
2
Pre-Chamber Gasket
18393-SDB-A00
1
Exhaust Pipe Gasket (ISHINO)
18212-SA7-003
2
Self-Lock Nut (10 mm)
90212-SA5-003
9
Bolt (12 point 8 x 21 mm) (AWD Only)
90113-S10-000
8
Flange Bolt (10 x 29 mm) (AWD Only)
90382-SH9-003
2
Shaft Ring Seal Kit (AWD) (AWD Only)
06235-5L9-000
1
Flange Nut (12 mm)
90362-SZA-A00
4
Split Pin (3.0 x 22 mm)
94201-30220
2
Castle Nut (14 mm)
90365-STX-A00
2
Flange Bolt (12 x 30 mm)
90161-SHJ-A00
4
Flange Bolt (14 x 140 mm)
90165-TZ5-A10
2
Flange Bolt (14 x 125 mm)
90165-TK8-A00
2
Snap Ring (32 x 2.2 mm)
44319-STX-A01
1
Set Ring (32 x 2.2 mm)
44319-STX-A60
1
Flange Bolt (10 x 30 mm)
90163-SDB-A00
3
Steering Joint Yoke Bolt
90135-TG7-A50
1
Spindle Nut (24 mm)
90305-SD4-003
2
Flange Bolt (12 x 45)
90165-SDA-A00
1
Flange Bolt (10 x 30)
90103-SV4-013
3
EGR Pipe Gasket A
18716-R70-A01
1
EGR Pipe Gasket B
18719-R70-A01
1
1
Page 10 of 44
Exhaust Chamber Gasket (NIPPON LEAKLESS)
18115-5G0-A01
2
Self-lock Nut (8 mm)
90212-RCA-A01
8
Throttle Body Gasket (FRG-NOK)
17102-RLV-A01
1
Intake Manifold Gasket (FRG-NOK)
17101-RLV-A01
6
Flange Bolt (10 x 85)
90002-R70-A00
1
Timing Idler Bolt
14551-RCA-A01
1
Front Intake Manifold Base Gasket
17055-R9P-A01
1
Rear Intake Manifold Base Gasket
17065-R9P-A01
1
Injector Seal Set
16452-RLV-A00
1
O-Ring
91311-5A2-A01
1
Fuel Joint Pipe Set
16012-R9P-315
1
O-Ring (31.2 x 4.1 mm) (NOK)
91314-PH7-003
2
Front Water Passage Gasket (NIPPON LEAKLESS)
19411-5G0-A02
1
Rear Water Passage Gasket (NIPPON LEAKLESS)
19412-5G0-A01
1
EGR Valve Gasket (ISHINO GASKET)
18715-PB2-000
1
Thermostat Cover Seal (NIPPON THERMOSTAT)
19305-PNA-003
1
Rear Cylinder Head Gasket (NIPPON LEAKLESS)
12261-R9P-A01
1
Front Cylinder Head Gasket (NIPPON LEAKLESS)
12251-R9P-A01
1
Oil Filter
15400-PLM-A02
1
Radiator (DENSO)
19010-5J6-A01
1
Warmer Hose B (ATF)
19433-5J2-A00
1
Water Hose A
19521-5J6-A50
1
Water Hose B
19522-5J6-A00
1
Water Hose C
19523-5J6-A10
1
Warmer Hose A (ATF)
19432-5J2-A50
1
Water Hose (Upper)
19501-5J6-A10
1
Water Hose A (Lower)
19502-5J6-A50
1
Water Hose (Lower) (B)
19504-5J2-A50
1
Reserve Tank Tube A
19103-5J6-A00
1
Reserve Tank Tube B
19104-5J6-A00
1
Reserve Tank
19101-5J6-A00
1
Thermostat Cover Assembly
19315-RLV-A51
1
Reserve Tank Cap
19102-5J6-A00
1
Page 11 of 44
O-Ring (Denso)
91307-RTA-005
2
Reserve Tank Joint
19106-RSA-G00
1
Connecting Pipe
19505-5J2-A00
1
Water Passage
19410-5J2-A00
1
Cooler Kit (ATF) (order only if vehicle is equipped with
the accessory tow package)
06255-5EZ-316
Inlet Water Hose
79721-TZ5-A10
1
Outlet Water Hose
79725-TZ5-A11
1
1
REQUIRED MATERIALS – REPAIR PROCEDURE C
Part Name
Part Number
Quantity
ATF Type 3.1 (only if the vehicle is equipped with an accessory
cooler)
08200-9017
1
Honda Genuine Antifreeze/Coolant Type 2
OL999-9011
3
Honda Engine Oil 0W-20
08798-9063
7
Part Name
Part Number
Quantity
Coolant Flush Kit Pump and Filter Set
VSB02C000045
1
9 A/T Pressure Test Kit
VSB02C000046
1
9 A/T Bucket and Hose Set
VSB02C000047
1
9 A/T Adapter and Hardware Set
VSB02C000048
1
TOOL INFORMATION
NOTE:
• Each dealer was sent one of each of these tools. If you need additional tools, contact the Honda Tool and
Equipment Program at 888-424-6857.
• Individual items in the kit and sets are not available separately. You must order the complete kit or set.
Page 12 of 44
INSPECTION PROCEDURE
Inspect the date on the transmission warmer. The affected transmission warmers were built between April 28, 2015
(2015-04-28) and July 15, 2015 (2015-07-15).
•
•
If the build date is within the date range, go to REPAIR PROCEDURE A.
If the build date is before or after the date range, no further action is needed. Return the vehicle to the
customer.
Page 13 of 44
REPAIR PROCEDURE A
Raise the vehicle on a lift.
Remove the splash shield. Refer to the service information.
Remove the air cleaner. Refer to the service information.
Remove the intake air guide. Refer to the service information.
Remove the 12-volt battery. Refer to the service information.
Remove the battery box. Refer to the service information.
Remove the connector bracket. Refer to the service information.
Using commercially-available clamps, pinch off the coolant hoses.
Remove the coolant hoses from the transmission warmer.
Clean the connection points around the transmission fluid warmer pipes.
•
•
If the vehicle is not equipped with an accessory external cooler, go to step 12.
If the vehicle is equipped with an accessory external cooler, go to step 11.
Page 14 of 44
Detach the accessory transmission cooler hoses.
•
Remove the bolt and bracket as shown.
•
Push the retaining clip out, and detach the external accessory cooler lines.
Page 15 of 44
Remove the 3 hold down bolts and 2 fixing plate bolts to remove the transmission warmer. Place the warmer on a
clean surface.
Prepare the transmission warmer to check for leaks.
•
•
•
•
Remove the original ATF lines from the warmer.
NOTE: Be careful not to damage the lines as you will reuse them.
Install the pressure check tool as shown with the fixing plates and torque the bolts to 10 N·m (7 lb-ft).
Fill a bucket with warm water.
Connect shop air to pressurize the warmer and adjust the pressure check tool to 70 psi.
Page 16 of 44
Check the transmission warmer for leaks by submerging the warmer completely under the water and watching for
bubbles.
•
•
NOTE: Some bubbles are normal when the transmission warmer is first submerged and will come to a stop.
If there is a leak, there will be a steady stream of bubbles coming from the transmission warmer.
If there are no bubbles coming from the warmer, continue with the warmer replacement. Go to step 15.
If there are bubbles, take photos (see Photos) and check to see if the vehicle also overheated by checking the
customer responses on the RO.
- If the transmission warmer leaks, but the engine did not overheat, go to REPAIR PROCEDURE B.
- If the transmission warmer leaks, and the engine overheated, go to REPAIR PROCEDURE C.
Photos
If there are bubbles because of a leaking transmission warmer, take photos of the bubbles during the
pressure test, the transmission warmer serial number, and the VIN.
• The pressure test
Page 17 of 44
•
The transmission warmer serial number
•
VIN
NOTE:
• These photos must be submitted with any warranty claim where the transmission is replaced.
• Make sure you install the leaking transmission warmer on the original transmission to be returned to the
remanufacturing facility. Any transmission replacement claims that do not have the leaking warmer installed
on the returned transmission may be subject to debit.
• Any transmission replacement claims that do not include the required photos may be subject to debit.
Unacceptable Photos
Photos must corresepond to the warranty claim submittal standards. Photos may be rejected for the following
reasons:
• Out of focus and unreadable
• Too small of a file size
• Too dark
Page 18 of 44
Remove the two ATF lines from the transmission warmer, then remove the 4 O-rings on the pipes by gently pushing
the O-rings off with your fingers.
• If the vehicle is equipped with an external cooler, go to step 16.
• If the vehicle is not equipped with an external cooler, go to step 17.
NOTE:
- Do not use picks or screwdrivers to remove the O-rings as you may damage the sealing surface.
Remove the Jiffy-Tite fittings.
•
•
•
Remove the fitting by using two 19 mm wrenches. Use one wrench to hold the ATF tube, and remove the fitting
with the other.
Clean the pipes.
NOTE: Make sure your hands are clean, or wear gloves, to avoid contaminating the Jiffy-Tite fitting.
Remove the sealing cap by turning it ¼ turn to the right, then install the Jiffy-Tite fitting, and
torque it to 22 N·m (16 lb-ft).
Page 19 of 44
Clean the pipes, then install 4 new O-rings.
NOTE: Make sure your hands or gloves are clean to avoid contaminating the O-rings.
Coat the O-rings with ATF 3.1.
Install the original ATF warmer pipes onto the new transmission warmer using the fixing plates. Torque the bolts to
10 N·m (7 lb-ft).
Install the transmission warmer to the transmission. Install the ATF warmer pipes using fixing plates. Torque the
bolts to 10 N·m (7 lb-ft).
•
•
If the vehicle is equipped with an accessory external cooler, go to step 21.
If the vehicle is not equipped with an accessory external cooler, go to step 22.
Page 20 of 44
Install hose A to line A and hose B to line B as shown.
Connect the water bypass hoses. Make sure you align the paint marks on the ATF warmer lines with the paint
marks on the water bypass hoses as shown. Secure the water bypass hoses with the clamps.
Install the connector bracket.
Install the battery box and the 12-volt battery.
Install the intake air guide and the air cleaner.
Fill the engine with coolant.
Check the ATF, and adjust as needed. Refer to the service information.
NOTE: Make sure you use the recommended Honda ATF Type 3.1 if you have to add fluid. Using the wrong ATF
can affect shift quality.
Check for any ATF or coolant leaks.
Install the splash shield.
Page 21 of 44
REPAIR PROCEDURE B
NOTE:
• Use this procedure only if the transmission warmer failed the pressure test and the engine did not
overheat. If the engine overheated, go to REPAIR PROCEDURE C.
• Fill in the flush work sheet (provided in this service bulletin), and attach it to the RO.
Remove the transmission. Refer to the service information.
Engine and Heater Core Flush Procedure
Disconnect the upper and lower radiator hoses at the engine.
Disconnect the two heater hoses at the engine.
Disconnect the ATF warmer line (coolant).
Remove the thermostat housing.
Page 22 of 44
Remove the thermostat from the housing using a 32 mm socket. Push in on the thermostat, and twist the socket.
Once the thermostat has released from the housing, remove the thermostat.
Install the green rubber plug from the coolant flush kit into the thermostat water jacket as shown. To prevent the
plug from falling into the water passage, cover the opening with a shop towel.
Remove the shop towel, and install the thermostat housing without the thermostat.
Page 23 of 44
Using the three colored plugs from the flush kit, cap off both heater hoses and the ATF transmission warmer line as
shown.
Using commercially-available clamps, clamp the throttle body coolant lines as shown.
Remove the lid from the SUPPLY bucket, and install the large (1.5 in.) return hose with the T-fitting through the hole
in the lid as shown.
Page 24 of 44
Install the thermostat adaptor to the pump outlet hose.
Install the pump outlet hose to the thermostat housing.
Install the return hose to the water passage as shown, then fill the bucket with 4.5 gallons of fresh water, and install
the lid.
Page 25 of 44
Install the pump inlet line to the SUPPLY bucket lid as shown.
NOTE: If this is the first time using the pump, remove the priming plug, fill the pump with clean water, then reinstall
the plug.
Page 26 of 44
Turn on the pump, and let it run for 10 minutes.
After 10 minutes, turn the pump off and dump all the contents of the SUPPLY bucket into the waste coolant
container. Wipe off any oil residue from the bucket, refill the bucket with water, then repeat the flush 4 more times
(50 minutes total time flushing with water).
Substitute the water for coolant (OL999-9011), and run the pump for 10 minutes to circulate the fluid.
After 10 minutes, turn the pump off and dump all the contents of the SUPPLY bucket into the waste coolant
container. Refill the SUPPLY bucket with coolant, and run the pump for 10 minutes.
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Disconnect the pump outlet line from the engine, and remove the thermostat adaptor. Replace the outlet adaptor
with the 0.75 in. heater hose adaptor.
Remove the thermostat cover, remove the green rubber plug, and return it to the coolant flush kit. To prevent the
plug from falling into the water passage, cover the passage with a shop towel.
Connect the pump outlet hose to the heater hose as shown.
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Install the heater core return hose through the DUMP bucket lid.
Attach the heater core return hose to the heater hose as shown.
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Fill the SUPPLY bucket with water, and run the pump until the SUPPLY bucket is empty.
Empty the DUMP bucket into the waste coolant container.
Repeat the flush (steps 25 and 26) 3 more times.
Empty the DUMP bucket into the waste coolant container and wipe off any oil residue from the bucket.
Remove the pump and return hoses, throttle body hose clamps, and the three colored plugs from the vehicle.
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Reassemble Vehicle
Replace the accessory cooler, if equipped.
Replace the radiator, the 10 indicated coolant hoses, thermostat, coolant reserve tank and hoses, and the 2 ECT
sensor (1 and 2) O-rings. Refer to the image for the location of all the components.
NOTE:
• Make sure to remove the green rubber plug that was installed in the thermostat water jacket and return
it to the flush kit.
• When refilling the cooling system after the flush is complete, some oil may be present in the cooling
system. Thorough testing has shown the amount left over after the flush procedure is within acceptable
limits provided the flush procedure was followed completely.
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Install the new remanufactured transmission. To ensure proper shift quality, update the TCM and PCM as
necessary, then do the PCM idle learn, teach-in (Hydraulic Pressure Characteristic Calibration), and adaptation
(see Tech2Tech listed below). Refer to the service information.
PCM
Trim
Program IN (or later)
Program P/N (or later)
2WD with 9-Speed A/T
LVA640
37805-RLV-A640
AWD with 9-Speed A/T
LVA840
37805-RLV-A840
Trim
Program IN (or later)
Program P/N (or later)
2WD with 9-Speed A/T
EYA050
28101-5EY-A050
AWD with 9-Speed A/T
EZA060
28101-5EZ-A060
TCM
-
Automatic Transmission Removal and Installation
Tech2Tech “Power Up a One-Push Start Vehicle with the i-HDS – With Replaced Components”
Tech2Tech “9-Speed Transmission or TCM Replacement Procedure”
Give your warranty clerk the digital photos and RO. For the warranty claim to be paid, the three photos must be
included in the warranty claim. See ATTACHING PHOTOS TO A CLAIM for information about attaching photos to
warranty claims.
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REPAIR PROCEDURE C
NOTE: Use this procedure only if the transmission warmer failed the pressure test and the engine overheated.
If the engine did not overheat, go to REPAIR PROCEDURE B.
Remove the engine and transmission assembly. Refer to the service information.
Heater Core Flush Procedure
Connect the pump to the SUPPLY bucket.
Make sure the 0.75 in. heater hose adaptor is installed on the pump outlet hose, then connect the pump outlet hose
to the heater hose as shown.
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Install the return hose through the DUMP bucket lid, then install the lid on the bucket.
Attach the return hose to the heater hose as shown.
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Fill the SUPPLY bucket with water, and run the pump until the SUPPLY bucket is empty.
NOTE: If this is the first time using the pump, remove the priming plug, fill the pump with clean water, then reinstall
the plug.
Empty the DUMP bucket into the waste coolant container.
Repeat the flush 3 more times.
Remove the pump and return hose from the vehicle.
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Reassemble Vehicle
Replace the radiator, the 10 indicated coolant hoses, the thermostat, the water passage and water connecting pipe,
the coolant reserve tank, the 2 ECT sensor (1 and 2) O-Rings, and the coolant reserve tank and hoses. Refer to the
image for the location of all the components.
Install a new short block, the water connecting pipe, the water passage, new cylinder heads, and a new
remanufactured transmission. To ensure proper shift quality, update the TCM and PCM as necessary, then do the
PCM idle learn, teach-in (Hydraulic Pressure Characteristic Calibration), adaptation (see Tech2Tech listed below),
and CKP-pattern learn. Refer to service information.
PCM
Trim
Program IN (or later)
Program P/N (or later)
2WD with 9-Speed A/T
LVA640
37805-RLV-A640
AWD with 9-Speed A/T
LVA840
37805-RLV-A840
Trim
Program IN (or later)
Program P/N (or later)
2WD with 9-Speed A/T
EYA050
28101-5EY-A050
AWD with 9-Speed A/T
EZA060
28101-5EZ-A060
TCM
-
Automatic Transmission Removal and Installation
Tech2Tech “Power Up a One-Push Start Vehicle with the i-HDS – With Replaced Components”
Tech2Tech “9-Speed Transmission or TCM Replacement Procedure”
Give your warranty clerk the digital photos and RO. For the warranty claim to be paid, the three photos must be
included in the warranty claim. See ATTACHING PHOTOS TO A CLAIM for information about attaching photos to
warranty claims.
END
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VIN_____________________
RO______________________
Flush Work Sheet
(Check each box when completed.)
(Attach to the RO.)
ENGINE FLUSH
Prime pump.
Fill SUPPLY bucket with 4.5 gallons of plain water. Flush 5 times, wiping the bucket out between each flush.
Flush with plain water 10 min ___
Flush with plain water 10 min ___
Flush with plain water 10 min ___
Flush with plain water 10 min ___
Flush with plain water 10 min ___
Add 4.5 gallons coolant for the final 2 flushes.
Flush with coolant 10 min ___
Flush with coolant 10 min ___
HEATER CORE FLUSH
Attach flush hoses to heater core. Fill supply bucket with 4.5 gallons of plain water, and flush 4 times.
Flush with plain water ___
Flush with plain water ___
Flush with plain water ___
Flush with plain water ___
Disconnect flush hoses ____
Remove
thermostat ___
plug ____
END
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ATTACHING PHOTOS TO A CLAIM
Go to the Photo Attachments area of the claim form to upload images as shown below.
To attach photos to the claim, click on Upload Images.
The Claim Photo Attachment screen appears.
Click on Browse. The Choose File to Upload window appears.
Click on an image file to be uploaded.
Click on Open to select the file.
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Click on Preview if you would like to view the image before uploading. The preview image appears.
Fit To Window is selected by default as the size at which the preview image is displayed. Click on Full Size if you
want to enlarge the image, and use the scrollbars to view different areas of the enlarged image.
Click on Upload to attach the image to the warranty claim.
The Uploaded Images count increases each time you upload a photo.
Click on Browse again and follow the same steps to continue attaching images to the claim. To properly document
each warranty repair claim, at least 3 photos must be attached.
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When finished attaching photos, click on Close.
The file names of your attached photos now appear in the Photo Attachments area of the claim form, as shown
below.
VIEWING AND DELETING PHOTO ATTACHMENTS
After uploading photo attachments, you can view the photos by clicking on View Images in the Photo Attachments
area. The Claim Photo Attachment screen displays thumbnails of all photos attached to the claim.
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Click on a thumbnail to view the photo attachment as shown above. To delete a photo attachment, simply click on
Delete to the left of its thumbnail.
When your claim and photos are completely ready, click on Submit to send the claim to the American Honda Warranty
department.
WARRANTY CLAIM PHOTO ATTACHMENT INQUIRY
After submitting a warranty claim, you can view its photo attachments at any time as follows:
1. Click on Service > Warranty > Warranty Claim Photo Attachment Inquiry.
2. Enter any of the following: Claim Number, VIN, Repair Order Number, or Repair Order Date.
3. Click on submit. Thumbnails of all photos attached to the claim appear, as shown below.
4. Click on any thumbnail to view the photo attachment.
NOTE:
• Photo attachments are archived on the iN for 2 years.
• Whenever you open a saved warranty claim and attach or delete photos, you must either save or submit the
claim to retain your photo attachment changes.
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CORRECTING PHOTO PROBLEMS USING PICTURE MANAGER
Microsoft Office Picture Manager is a very useful tool to help improve the quality of photos submitted for warranty
consideration.
While the Picture Manager program cannot correct blurry, out-of-focus pictures, it can adjust pictures for brightness,
contrast, and color, helping to reveal details. It can also crop or resize digital photo files so that they can be submitted
for warranty claim consideration.
• To use this program on your PC, click on Start > Programs > Microsoft Office > Microsoft Office Tools >
Microsoft Office Picture Manager.
• If the above instruction does not lead you to the Picture Manager program, click on Start > Search. Under Search
for Folders or Files, enter Picture Manager in the Search window, then click on Search Now.
• To create a shortcut to open Microsoft Picture Manager from your desktop, go to Start > Programs > Microsoft
Office >Microsoft Office Tools > Microsoft Picture Manager >, then right-click and choose Create Shortcut.
The shortcut icon and title will appear below the original Microsoft Picture Manager icon and title. Left-click and hold
on the shortcut icon and drag it to the desktop. Once there, if you wish to change its name, right-click on the icon
and select Rename.
• To open and edit photos directly from Microsoft Picture Manager, right-click on any JPEG picture file, then move
your cursor to Open with.
Another window will open listing Microsoft Office Picture Manager and other programs. Do not click on Picture
Manager, but instead scroll down the list, then click on Choose Program.
Another window will open, with Picture Manager already selected. Check the open box next to Always use the
selected program to open this kind of file; this will make Picture Manager your default picture management
program.
NOTE: The next time you click on a JPEG photo, it will automatically open in the Picture Manager program.
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Correction Example #1: Photo is Too Dark
In Picture Manager, select Edit/Edit Pictures > Edit Using These Tools/Brightness and Contrast. Use the sliding
scales to adjust the photo to the brightness and contrast that best reveal the fault.
Before Picture Manager Correction
After Picture Manager Correction
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Correction Example #2: Photo Size is Too Large
For maximum clarity, the file size for each photo must be between 500 kB and 10,000 kB (10 mB). ZIP-compressed
files are not acceptable. Photo file sizes over 10,000 kB (10 mB) cannot be accepted by the American Honda
Warranty department.
To reduce a picture's file size, open Picture Manager. Click on the photo to be reduced, then click on Edit Pictures >
Resize > Percentage of original width x height, then click on the down arrow to reduce its percentage (%) size.
View the pixel count change in Size Setting Summary, which displays the photo's Original size and its New size.
NOTE: The % function changes the pixels per inch, so a photo’s size should be reduced only enough to meet the
maximum file size requirement. For example, a 10% reduction in pixels per inch will reduce a photo's size and its
resolution by almost 50%.
END
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