Campaign - Cylinder Head Assembly Replacement: Overview

08-032

July 11, 2008

Applies To:
See VEHICLES AFFECTED

Product Update: Engine Makes a Clicking or a Tapping Noise
(Supersedes 08-032, dated May 16, 2008, to update the information marked by the black bar)

BACKGROUND

During engine assembly, an incorrect exhaust rocker arm shaft may have been installed. The incorrect shaft does not allow proper lubrication to the camshaft journals, which results in excessive heat buildup. In some cases, the camshaft holder bolts loosen, allowing the rocker arm shaft to move and causing a clicking or a tapping noise.





VEHICLES AFFECTED

CUSTOMER NOTIFICATION

All owners of affected vehicles will be mailed a notification of this product update. An example of the customer notification is at the end of this service bulletin.

Before beginning work on a vehicle, verify its eligibility by checking at least one of these items:

^ The customer has a notification letter.

^ The vehicle is shown as eligible on a VIN status inquiry.

In addition, check for a punch mark above the first character of the engine compartment VIN. A punch mark in that location means this product update has already been completed.

CORRECTIVE ACTION

Replace the cylinder head assembly.

NOTE:
The loss of lubrication is only in the camshaft and rocker arm area. There is no need to replace the short block assembly.

PARTS INFORMATION

Cylinder Head Assembly:
P/N 10003-RRB-A02, H/C 8600066

Cylinder Head Gasket Kit:
P/N 06110-RRB-A01, H/C 8352189

Coolant Separator
P/N 11103-RAC-003, H/C 8144735

Retainer (Green):
P/N 17711-S0X-A31, H/C 5928288

REQUIRED MATERIALS

Hondabond HT:
P/N 08718-0001, H/C 2963817
(One Hondabond HT tube repairs about 10
vehicles.)

5W-20 Motor Oil (Quart Bottle):
P/N 08798-9023, H/C 6512610
(Each repair requires 4.4 quarts.)





WARRANTY CLAIM INFORMATION

Failed Part: P/N 10003-RRB-A02
H/C 8600066

Defect Code: 5R500

Symptom Code: Q8300

Skill Level: Repair Technician

INSPECTION PROCEDURE

1. Remove the cylinder head cover:

^ Refer to page 6-85 of the 2006-2008 Civic Service Manual, or

^ Online, enter keywords HEAD COV, and select Cylinder Head Cover Removal (K20Z3 Engine) from the list.

2. Inspect the exhaust rocker arm shaft through the slots in all four rocker arms as shown. You should see that the rocker arm shaft is solid inside all of the slots.

NOTE:
If you cannot clearly see into the slots in the rocker arm, use a pick tool to feel for the rocker arm shaft.

^ If the rocker arm shaft is not solid at any of the rocker arm slots, go to REPAIR PROCEDURE.

^ It the rocker arm shaft is solid inside all of the slots, reinstall all removed parts, then go to step 4 of REPAIR PROCEDURE.

REPAIR PROCEDURE

1. Remove the cylinder head:

^ Refer to page 6-87 of the service manual, or

^ Online, enter keywords CYL REM, and select Cylinder Head Removal (K20Z3 Engine) from the list.

2. Install the new cylinder head assembly:

^ Refer to page 6-106 of the service manual, or

^ Online, enter keywords CYL INSTALL, and select Cylinder Head Installation (K20Z3 Engine) from the list.

3. Replace the engine oil (4.4 qt).





4. Center-punch a completion mark above the first character of the engine compartment VIN.





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