Engine - Engine Block Extended Warranty
10-048June 17, 2011
Applies To:
See VEHICLES AFFECTED
Warranty Extension: Engine Block
(Supersedes 10-048, dated December23, 2010, to revise the information marked by the black bars and asterisks)
REVISION SUMMARY
*Under PARTS INFORMATION, the cylinder head gasket kit part number was changed.*
BACKGROUND
On some 2006-08 and early production 2009 Civics, the engine (cylinder) block may experience engine coolant leaks, resulting in engine overheating. To increase customer confidence, American Honda is extending the warranty of the engine block to 8 years from the original date of purchase, with no mileage limit.
The warranty extension does not apply to any vehicle that has ever been declared a total loss or sold for salvage by a financial institution or insurer, or has a branded, or similar title under any states law. To check for vehicle eligibility, you must do a VIN status inquiry.
VEHICLES AFFECTED
CUSTOMER NOTIFICATION
All owners of affected vehicles will be sent a notification of this warranty extension. An example of the customer notification is at the end of this service bulletin.
Before beginning work on a vehicle, verify its eligibility by doing a VIN status inquiry and by making sure the customer has a notification letter.
CORRECTIVE ACTION
If confirmed by your diagnosis, install a new engine block.
PARTS INFORMATION
REQUIRED MATERIALS
WARRANTY CLAIM INFORMATION
If you are repairing an engine block because of coolant leaking from the block or engine overheating relating to coolant seepage, and the vehicle is within the warranty extension period, 8 years from the original date of purchase and no mileage limit, use the information below to submit a claim.
Operation Number: 1111P8
Flat Rate Time: 12.4 hours
Failed Part: P/N 10002-RNA-AOO
Defect Code: 5E200
Symptom Code: R4300
Skill Level: Repair Technician
DIAGNOSIS
Look for coolant leaking from cracks in the block at the points shown below. On the back side of the engine, remove the oil/air separator cover so you can check beneath it. Pressure4est the cooling system if needed.
Is the block leaking coolant in any of the areas shown?
Yes - Go to REPAIR PROCEDURE.
No - Continue with normal troubleshooting.
REPAIR PROCEDURE
1. Remove the engine and transmission assembly:
^ Refer to page 5-3 of the 2006-2011 Civic Service Manual, or
^ Online, enter keywords ENGINE REMOVAL, and select Engine Removal (R18A1 Engine) from the list.
2. Remove the ignition coils:
^ Refer to page 4-28 of the service manual, or
^ Online, enter keywords IGNITION COIL, and select Ignition Coil Removal/Installation (R18A1 and R18A4 Engine) from the list.
3. Inspect the ignition coils for lengthening due to overheating.
Is there a gap in the insulation greater than 1 mm (0.04 inch)?
Yes - Replace the affected coil(s).
No - Re-use the original coil(s).
4. Remove the cylinder head:
^ Refer to page 6-28 of the service manual, or
^ Online, enter keywords HEAD REMOVE, and select Cylinder Head Removal (R18A1 Engine) from the list.
5. Inspect the cylinder head:
^ Refer to steps 2 and 3 on page 6-33 of the service manual, or
^ Online, enter keywords HEAD INSPECT, and select Cylinder Head Inspection for Warpage (R18A1 and R18A4 Engine) from the list, and do steps 2 and 3.
6. Remove the engine oil pump, and set it aside for use later:
^ Refer to page 8-15 of the service manual, or
^ Online, enter keywords OIL PUMP, and select Oil Pump Overhaul from the list.
7. M/T only: Remove the M/T from the engine:
^ Refer to page 13-92, beginning with step 31, of the service manual, or
^ Online, enter keywords TRANS REMOVAL, and select Manual Transmission Removal (5M/T) from the list.
8. A/T only: Remove the A/T from the engine:
^ Refer to page 14-181, beginning with step 7, of the service manual, or
^ Online, enter keywords TRANS REMOVAL, and select Automatic Transmission Removal (A/T) from the list.
9. Install the original oil pump on the new engine block assembly with new 0-rings and a new seal.
NOTE:
Refer to Install Crankshaft Pulley Correctly to Prevent Oil Pump Damage," ServiceNews, December 2007.
10. Install the original cylinder head on the new engine block assembly:
NOTE:
Be sure to install the partition plate (coolant separator) before installing the cylinder head.
^ Refer to page 6-48 of the service manual, or
^ Online, enter keywords HEAD INSTALL, and select Cylinder Head Installation (R18A1 Engine) from the list.
11. M/T only: Install the new crankshaft pilot bearing, and the original flywheel, clutch, and pressure plate onto the engine:
^ Refer to page 12-18 of the service manual, or
^ Online, enter keyword CLUTCH, and select Clutch Replacement (5M/T) from the list.
12. M/T only: Install the M/T onto the engine:
^ Refer to page 13-16 of the service manual, or
^ Online, enter keywords TRANS INSTALLATION, and select Manual Transmission Installation (5M/T) from the list.
13. A/T only: Install the original drive plate onto the engine:
^ Refer to page 14-189, beginning with step 3, of the service manual, or
^ Online, enter keywords AUTO TRANS, select Drive Plate Removal and Installation from the list, and begin at step 3.
14. A/T only: Install the A/T onto the engine:
^ Refer to page 14-190, beginning with step 3, of the service manual, or
^ Online, enter keywords TRANS INSTALLATION, select Automatic Transmission Installation (A/T) from the list, and begin at step 3.
15. Install the engine and transmission assembly into the vehicle:
^ Refer to page 5-13 of the service manual, or
^ Online, enter keywords ENGINE INSTALL, and select Engine Installation (RI 8A1 Engine) from the list.
^ To avoid electrical problems, make sure that the ground wire connection G101 (Photo 29 ETM) is clean and tight.
^ To avoid coolant mixing in the gas tank, make sure you do not confuse the canister purge line with the coolant bypass hose.
16. To avoid false misfire detection, do the crank (CKP) pattern clear and CKP pattern learn procedures:
^ Refer to page 11-4 of the service manual, or
^ Online, enter keywords HOW TO
TROUBLESHOOT FUEL, and select How to
Troubleshoot Fuel and Emissions Systems
(R18A1 Engine, A/T), or (R18A1 Engine, M/T)
from the list.
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