Accessory
INSTALLATION
INSTRUCTIONS
Application
FOG LIGHT KIT
(WITHOUT FRONT BUMPER
LOWER TRIM)
Publications No.
AII 25856-26827
2004 PILOT
P/N 08V31-S9V-110
Fog Light Kit
4 Collars
Right fog light
Relay with rubber
Issue Date
FEB 2004
Relay
Left fog light
27 Wire ties
Right fog light bracket
8 Washer-screws, 5 x 16 mm
4 Washer-screws, 4 x 12 mm
Left fog light bracket
Fuse label A
Switch harness
3 Washer-bolts
3 Flange nuts
Fog light harness
Unit bracket
Switch
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
08V31-S9V-1000-91
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Fusible link
Nut
2 Wire ties with holder
Control unit bracket
Right fog light cover
Left fog light cover
TOOLS AND SUPPLIES REQUIRED
Phillips screwdriver
Flat-tip screwdriver
Ratchet
10 mm and 12 mm Sockets
Diagonal cutters
40 mm Hole saw
Utility knife
Hacksaw blade
10 mm Combination wrench
Cardboard or blanket
Drill
3 mm and 9 mm Drill bits
Torque wrench
Pushpin
File
Ruler
Felt-tip pen
Clip remover
Isopropyl alcohol
Shop towel
Illustration of Fog Lights Installed on the Vehicle
FUSIBLE LINK
2 Subbrackets
RELAY
FOG LIGHT
HARNESS
SWITCH
4 Self-tapping screws, 5 x 16 mm
4 Clip nuts
EPT sealer
4 Self-tapping screws, 5 x 20 mm
RIGHT FOG
LIGHT
Fuse label B
SWITCH
HARNESS
LEFT FOG
LIGHT
RELAY WITH
RUBBER
2 Washers
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AII 25856-26827 (0402)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
INSTALLATION
4.
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.”
1.
Make sure you have the anti-theft code for the
radio, then write down the radio station presets.
2.
Disconnect the negative cable from the battery.
Remove the front bumper (four short clips, two
self-tapping screws, four bolts, and two long
clips).
SHORT CLIP
SELFTAPPING
SCREW
Routing the Fog Light Harness
3.
FRONT
BUMPER
Open the hood. Remove the bulkhead cover
(11 clips).
BOLT
SELFTAPPING
SCREW
CLIPS (11)
SHORT
CLIP
BOLT
5.
LONG
CLIP
BOLT
SHORT
CLIP
BOLT
Remove the wire cable clip and the tube from the
air cleaner case.
BOLT
AIR CLEANER
CASE
TUBE
BULKHEAD
COVER
BOLT
WIRE CABLE CLIP
6.
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
Remove the air cleaner case (2 bolts), and remove
the air cleaner assembly. Be careful not to
damage the vehicle harness.
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7.
Lift the cover on the positive battery cable, and
route the terminal end of the fusible link through
the cover.
10. Route the fog light harness between the vehicle
harness and the body panel alongside the vehicle
harness and under the left headlight.
FUSIBLE LINK
TERMINAL
FOG LIGHT
HARNESS
NUT
COVER
FRONT
VEHICLE
GROUND
BOLT
(Reuse.)
FOG LIGHT
HARNESS
GROUND
TERMINAL
VEHICLE
HARNESS
VEHICLE
GROUND
TERMINAL
BATTERY
POSITIVE
CABLE
FUSIBLE
LINK
8.
Attach the terminal of the fusible link to the
positive cable of the battery with the nut provided.
Secure the positive cable.
FOG LIGHT
HARNESS
CONNECTOR
FOG LIGHT
HARNESS
FUSIBLE LINK
CONNECTOR
VEHICLE
HARNESS
FOG LIGHT
HARNESS
LEFT
HEADLIGHT
11. Remove the vehicle ground bolt, and secure the
fog light harness ground terminal using the ground
bolt.
POSITIVE
BATTERY COVER
12. Pull the fog light harness out from under the left
headlight.
9.
Reinstall the cover on the positive battery cable.
Get the fog light harness. Plug the fusible link
connector into the fog light harness connector.
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AII 25856-26827 (0402)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
13. On the left front bulkhead, locate the 1-pin
connector blue-taped to the vehicle harness.
Remove the blue tape to free the connector. Plug
the 1-pin connector you just freed into the 1-pin
connector of the fog light harness.
15. Route the long end of the fog light harness 2-pin
connector under the left horn and into the engine
compartment.
FOG LIGHT HARNESS
(long end)
BLUE TAPE
LEFT HORN
VEHICLE
1-PIN
CONNECTOR
WASHERBOLT
LEFT FRONT
BULKHEAD
FLANGE
NUT
LEFT FRONT
BULKHEAD
FOG LIGHT
HARNESS
VEHICLE HARNESS
1-PIN CONNECTOR
FOG LIGHT
HARNESS
FOG LIGHT HARNESS
1-PIN CONNECTOR
UNIT
BRACKET
RELAY
WITH
RUBBER
FOG LIGHT
HARNESS 4-PIN
CONNECTOR
16. Attach the unit bracket to the left front bulkhead
with a flange nut and a washer-bolt.
14. Position the relay with rubber on the unit bracket,
and install them with a flange nut and a washerbolt.
17. Plug the fog light harness 4-pin connector into the
relay with rubber.
FLANGE NUT
UNIT
BRACKET
WASHER-BOLT
RELAY WITH
RUBBER
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
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18. Route the fog light harness alongside the vehicle
harness and above the fan shroud toward the right
(passenger's) side of the vehicle.
20. At the battery, clip the wire tie with holder onto the
fog light harness connector, and attach this wire
tie to the vehicle harness.
FOG LIGHT
HARNESS
CONNECTOR
FRONT
FOG LIGHT
HARNESS
WIRE TIE
WITH HOLDER
VEHICLE
HARNESS
FOG LIGHT
HARNESS
FAN SHROUD
19. Continue routing the fog light harness under the
vehicle harness to the right side of the vehicle,
then pull the harness out from under the right
headlight through the opening near the right horn.
FRONT
RIGHT
HEADLIGHT
21. Along the side of the battery, secure the fog light
harness to the vehicle harness with three wire ties
in the areas shown.
WIRE TIE
FRONT
Route the fog
light harness
under the vehicle
harness.
FOG LIGHT
HARNESS
RIGHT
HORN
VEHICLE
HARNESS
FOG LIGHT
HARNESS
WIRE TIE
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AII 25856-26827 (0402)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
22. At the 1-pin connector, secure the fog light
harness to the vehicle harness with three wire ties
in the areas shown.
26. Above the fan shroud, secure the fog light harness
to the vehicle harness with five wire ties.
WIRE TIE
WIRE TIE
VEHICLE
HARNESS
WIRE TIE
VEHICLE
HARNESS
FOG LIGHT
HARNESS
FOG LIGHT
HARNESS
23. Secure the fog light harness to the vehicle
harness with the four wire ties.
WIRE TIE
VEHICLE HARNESS
27. Below the right headlight, secure the fog light
harness to the vehicle harness with two wire ties.
FOG LIGHT
HARNESS
WIRE TIE
WIRE TIE
FOG LIGHT
HARNESS
FOG LIGHT
HARNESS FUSE
CASE
FUSE
LABEL A
(20A)
WIRE TIE WITH
HOLDER
FOG LIGHT
HARNESS
FOG LIGHT
HARNESS
VEHICLE
HARNESS
WIRE TIE
24. Attach the fuse label A (FOG LIGHT 20A) to the
fuse case on the fog light harness.
VEHICLE
HARNESS
25. Slide the holder from the wire tie with holder onto
the fog light harness fuse case, then attach one
wire tie with holder to the vehicle harness and the
fog light harness in the area shown.
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
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Installing the Fog Lights
Check on the inside of the front bumper for reference
marks; if there are no reference marks, continue with
step 28: otherwise, go to step 33.
28. Make a copy of the left and right side templates
(last two pages). Using scissors, cut out the left
template along the outer edge.
30 Position the left template on the inside of the front
bumper, and align the two outer marks of the
template with the two holes you made in the
bumper. Align the other end of the template with
the scribed line on the front bumper. Use strips of
tape and two pushpins to hold the template in
place.
HOLES made
in step 29.
LEFT TEMPLATE
(Copy last two pages.)
Align the
right end
of the left
template
with the
scribed
line on
the front
bumper.
PUSHPIN
29. On the inside of the front bumper, locate the two
marks scribed into the bumper. Using a pushpin,
pierce through the bumper at the two marks.
LEFT
TEMPLATE
SCRIBED LINE
FRONT
BUMPER
MASKING
TAPE
LEFT TEMPLATE
31. Using a pushpin, pierce through the bumper at the
remaining 5 places on the template.
BACK OF
FRONT
BUMPER
Do not mark these
holes, they are for
the front bumper
lower trim.
Pierce through the
bumper in 5 places.
PUSHPIN
PUSHPIN
SCRIBED
MARKS
LEFT
TEMPLATE
FRONT
BUMPER
32. Get the right template and repeat steps 29 thru 31
to mark the right side side of the front bumper,
then go to step 34.
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AII 25856-26827 (0402)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
33. On the inside of the front bumper, locate the
seven marks scribed into the bumper. Use a
pushpin to make holes through the front bumper at
each of the seven marks.
35. Using a 40 mm hole saw, drill through each of the
remaining five marks of the front bumper.
MARKS (7)
FRONT BUMPER
OUTER SURFACE
PUSHPIN
BACK OF
FRONT BUMPER
MARKS (5)
40 mm
HOLE SAW
Do not mark these
holes, they are for
the front bumper
lower trim.
34. While wearing eye protection, drill a 9 mm hole
through each of the two outboard marks you
made. Drill from the outer surface inward, first with
a 3 mm drill bit. Remove any burrs from the edges
of the holes with a file.
36. On the inside of the front bumper, use a ruler and
felt-tip pen to make a line between the corners of
the five holes. Using a hacksaw blade, cut out the
marked area from the front bumper along the
scribed lines. Remove any burrs from the edge of
the holes.
BACK OF
FRONT BUMPER
MARK
FRONT BUMPER
OUTER SURFACE
Cut out the
marked area.
HACKSAW
BLADE
MARK
DRILL
(First with a 3 mm drill bit,
and finish with a 9 mm
drill bit)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
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37. Get the left fog light and the left fog light bracket.
Insert the slot of the left fog light into the aiming
adjusting screw, then install the two 5 x 16 mm
washer-screws. Position the connector near the
connector stay.
WASHERSCREW
(5 x 16 mm)
LEFT
FOG LIGHT
BRACKET
39. Position the left fog light bracket against the front
bumper, and install two 5 x 16 mm washer-screws
and two collars from the front bumper.
CONNECTOR
STAY
LEFT
FOG LIGHT
BRACKET
COLLARS (2)
AIMING ADJUSTER
SCREW
LEFT
FOG
LIGHT
SLOT
FRONT
BUMPER
OUTER
SURFACE
SLOT
WASHERSCREW
(5 x 16 mm)
AIMING
ADJUSTER
SCREW
WASHER
WASHERSCREW
38. On the inside of the front bumper near the hole
you cut, remove and discard the two self-tapping
screws from the bumper. Position the left fog light
bracket on the left mounting bosses, and install
two 5 x 20 mm self-tapping screws and the
washer.
WASHER
LEFT FOG
LIGHT
BRACKET
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COLLAR
FRONT
BUMPER
40. Repeat steps 28 thru 39 to install the right fog light
onto the right fog light bracket at the right side of
the front bumper.
INSIDE OF
FRONT BUMPER
SELFTAPPING
SCREW
(5 x 20 mm)
VEHICLE
SELF-TAPPING
SCREW
(Discard.)
AII 25856-26827 (0402)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
41. While holding the front bumper close to the
vehicle, connect the 2-pin connectors of the fog
light harness to the right and left fog lights, then
reinstall the front bumper. Make sure that all clips
and retaining tabs are installed securely.
Routing the Switch Harness
43. Remove the fuel lid door opener knob.
RETAINING TAB
FUEL LID DOOR
OPENER KNOB
FOG LIGHT HARNESS
2-PIN CONNECTOR
LEFT FRONT
DOOR SILL TRIM
CLIP
FRONT BUMPER
FOG LIGHT
2-PIN CONNECTOR
42. On each side, pull the 2-pin connectors out from
between the fog light brackets, and slide the 2-pin
connectors onto the fog light bracket stays.
CLIPS (2)
44. Remove the left front door sill trim (three clips and
two retaining tabs).
45. Remove the weatherstrip from the left kick panel.
WEATHERSTRIP
CLIP
LEFT KICK
PANEL
FOG LIGHT
CONNECTOR
STAY
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
FOG LIGHT
2-PIN CONNECTOR
CLIP
46. Remove the upper clip from the left kick panel,
then pull the left kick panel out toward you to
release the remaining clip.
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With Automatic Day/Night Mirror:
47. Remove the left dashboard side cover (four clips,
one retaining tab, and seven hooks). Use a clip
remover to release the clips.
If you are also installing an accessory automatic
day/night mirror, connect the 6-pin connectors
from the automatic day/night mirror between
the upper switch harness 6-pin (gray) connector
(gray) and the fuse box.
HOOKS (7)
FUSE BOX 6-PIN
CONNECTOR
AUTOMATIC DAY/NIGHT
MIRROR HARNESS 6-PIN
CONNECTOR
CLIPS (4)
RETAINING TAB
LEFT DASHBOARD
SIDE COVER
SWITCH
HARNESS
48. Get the switch harness. Plug the two 6-pin
connectors of the switch harness into the two
6-pin connectors on the fuse box.
UPPER SWITCH HARNESS
6-PIN CONNECTOR (gray)
SWITCH HARNESS
6-PIN CONNECTOR
Without Automatic Day/Night Mirror:
FUSE BOX
49. Remove and discard the switch cover from the
switch panel.
UPPER SWITCH HARNESS
6-PIN CONNECTOR (gray)
Hole in side frame of
instrument panel
SWITCH
PANEL
SWITCH
HARNESS
SWITCH
HARNESS
5-PIN
CONNECTOR
SWITCH HARNESS
6-PIN CONNECTOR (blue)
VEHICLE
HARNESS
FUSE BOX
6-PIN
CONNECTOR
SWITCH COVER
(Discard.)
50. At the left dashboard opening, route the switch
harness 5-pin connector up alongside the vehicle
harness and through the hole in the side frame,
and pull the connector out through switch hole.
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AII 25856-26827 (0402)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
51. Get the relay and the control unit bracket. Position
the relay on the control unit bracket, and install
the washer-bolt and flange nut.
54. Unplug the vehicle 20-pin connectors and connect
the switch harness 20-pin connectors in between.
VEHICLE 20-PIN
CONNECTOR
LARGE
HOLE
SWITCH
HARNESS
CONTROL UNIT
BRACKET
FLANGE
NUT
WASHERBOLT
SMALL
HOLE
RELAY
52. Route the switch harness 2-pin connector above
the vehicle harness near the parking brake
bracket, and plug the switch harness 2-pin
connector into the vehicle harness 2-pin
connector.
SWITCH HARNESS
20-PIN CONNECTOR
VEHICLE
HARNESS
SWITCH
HARNESS
FUSE CASE on
SWITCH HARNESS
55. Plug the switch harness 4-pin connector into the
small relay.
FUSE
LABEL B
(2A)
SWITCH HARNESS
2-PIN CONNECTOR
SMALL
RELAY
PARKING BRAKE
BRACKET
CONTROL UNIT
BRACKET
STEERING HANGER
BEAM BRACKET
VEHICLE
HARNESS
2-PIN
CONNECTOR
VEHICLE
BOLT
53. Attach the OPTION 2A fuse label from fuse label
"B" to the switch harness fuse case.
SWITCH
HARNESS
SWITCH HARNESS
4-PIN CONNECTOR
56. Remove the rear bolt that secures the steering
hanger beam bracket, and attach the control unit
bracket with this bolt. Torque the steering hanger
bracket to 19 to 24 N·m (14 to 18 lb-ft).
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
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57. Secure the switch harness to the vehicle
connector on the stop switch harness with one
wire tie at the green tape. Secure the switch
harness to the vehicle harness with three wire ties
in the areas shown.
VEHICLE
HARNESS
WIRE TIE
VEHICLE
CONNECTOR
59. At the dashboard opening, secure the switch
harness to the vehicle harness with two wire ties.
SWITCH
HARNESS
GREEN
TAPE
VEHICLE
HARNESS
SWITCH
HARNESS
STOP
SWITCH
WIRE TIE
WIRE TIE
PARKING BRAKE BRACKET
60. Plug the switch harness 5-pin connector into the
switch, then install the switch on the switch panel.
58. Continue to secure the switch harness to the
vehicle harness with four wire ties in the areas
shown.
VEHICLE
HARNESS
WIRE TIE
SWITCH
HARNESS
SWITCH HARNESS
5-PIN CONNECTOR
SWITCH
SWITCH
PANEL
WIRE TIE
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VEHICLE
HARNESS
WIRE TIE CLIP
AII 25856-26827 (0402)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
Adjusting the Fog Light Aiming
Installing the Fog Light Cover
61. Adjust the fog light:
69. Using scissors, cut one EPT sealer into three
pieces using the measurements shown.
•
•
Adjust the aiming according to local laws and
regulations.
To adjust, turn the aiming adjustment screw in
or out until the correct aiming is obtained.
70. Using isopropyl alcohol on a shop towel, clean the
subbracket where the 1/4 piece of the EPT sealer
will attach, then attach that piece to the
subbracket.
EPT SEALER
30 30
mm mm
Using isopropyl
alcohol on a shop
towel, clean this
area.
CLIP
NUTS (2)
SELF-TAPPING
SCREWS (2)
(5 x 16 mm)
To
raise
To
lower
PHILLlPS
SCREWDRIVER
EPT SEALER
(1/4)
AIMING
ADJUSTMENT
SCREW
62. Check that all wire harnesses are routed properly
and all connectors are plugged in.
63. Reinstall all removed parts. Check that all clips
and other fasteners are installed securely.
64. Reconnect the negative cable to the battery.
SUBBRACKET
LEFT
FOG LIGHT
COVER
71. Slide the two clip nuts into the openings of the left
fog light cover. Position the subbracket on the left
fog light cover, and install the two 5 x 16 mm selftapping screws.
72. Using isopropyl alcohol on a shop towel, clean the
subbracket in the area shown, then attach the cut
piece of the EPT sealer to the subbracket.
Using isopropyl
alcohol on a shop
towel, clean this area.
65. Reset the clock, and reset the radio station
presets.
NOTE: Whenever the battery is disconnected, the
driver’s window AUTO function is disabled.
CLIP
NUTS (2)
66. Start the engine. Push down on the driver’s
window switch until the window is fully open.
SELF-TAPPING
SCREWS (2)
(5 x 16 mm)
67. Pull up on the driver’s window switch to close the
window completely, then hold the switch for
2 seconds or more.
68. Lower and raise the window to check the operation
of the driver's window AUTO function.
SUBBRACKET
RIGHT FOG
LIGHT COVER
EPT
SEALER
(1/4)
73. Repeat step 71 to install the right fog light cover to
the bracket.
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
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74. Fit the left fog light cover into place on the front
bumper, and install the two 4 x 12 mm washerscrews.
Replacing the Fog Light Bulb
1.
Remove the fog light cover (two screws).
HOLE in front bumper
SUBBRACKET
LEFT FOG
LIGHT
BRACKET
WASHERSCREW
(4 x 12 mm)
LEFT FOG
LIGHT COVER
75. Repeat step 74 to install the right fog light cover.
FOG LIGHT
COVER
USE AND CARE
SCREW
How to Operate Fog Lights
•
•
Turn the light switch to the “
on low beam ).
” position (headlights
2.
Remove the fog light connector from the
connector stay, and unplug the connector.
Press the fog light switch (indicator is on).
The fog light lenses can cloud when the outside
temperature is cold; this is normal and should go away
in warm weather.
SCREW
(Loosen.)
CONNECTOR
STAY
SCREW
(Remove.)
FOG LIGHT
3.
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AII 25856-26827 (0402)
FOG LIGHT
HARNESS
CONNECTOR
FOG LIGHT
CONNECTOR
Loosen the slotted screw, remove the other screw,
and remove the fog light.
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
4.
Remove the rear cover from the left fog light (five
screws).
6.
Install the new bulb into the socket.
•
SCREWS (5)
Use only a genuine Honda halogen light bulb of
specified wattage.
Rating: 12V 55W H3 Halogen Light Bulb
•
Do not touch the bulb. Oily or greasy
substances on the bulb can shorten its service
life due to the heat produced when the bulb is
turned on. If the bulb is accidentally touched,
wipe it clean with a soft cloth that has been
dampened with denatured alcohol or a mild
detergent solution.
•
Align the tab on the fog light with the cutout in
the bulb when installing the new bulb. If not
aligned, the fog light may annoy oncoming
drivers.
REAR COVER
FOG LIGHT
5.
Remove the retainer spring, and pull out the bulb
and socket as a unit. Replace the bulb with a new
one.
NEW BULB
BULB
RETAINER
SPRING
CUTOUT
TAB
HOOK
7.
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
Reinstall the removed parts in the reverse order of
removal.
•
Check that the wire harnesses are not pinched.
•
Make sure you tighten all of the screws
securely.
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CIRCUIT DIAGRAM
LEFT
HEADLIGHT
HI
LO
FOG LIGHT
FUSIBLE
LINK
R/Y
R/L
R/B
W
4-PIN
RELAY
PILOT LAMP (1 W)
FOG
SWITCH
ILLUMINATION
(1 W)
BATT.
O/W
ILLUMINATION (+)
FUSE
2A
20A
W/L
L
W/R
L/R
R
B
4-PIN
RELAY
ILLUMINATION
(-)
(55W x 2)
L/O
B
PASSENGER’S
COMPARTMENT
B
ENGINE
COMPARTMENT
LIGHT SWITCH
FOG LIGHT
SWITCH
OFF
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Low
Hi
OFF
ON
ON
AII 25856-26827 (0402)
B
BLACK
BR
BROWN
Y
YELLOW
O
ORANGE
L
BLUE
SB
SKY BLUE
G
GREEN
LG
LIGHT GREEN
R
RED
P
PINK
W
WHITE
GR
GRAY
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
LEFT SIDE TEMPLATE
L-SIDE
© 2004 American Honda Motor Co., Inc - All Rights Reserved.
AII 25856-26827 (0402)
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RIGHT SIDE TEMPLATE
R-SIDE
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AII 25856-26827 (0402)
© 2004 American Honda Motor Co., Inc - All Rights Reserved.