Engine, Cooling System - Overheating/Coolant Loss
08-044August 21, 2009
Applies To:
2006-08 Civic - ALL except GX, Hybrid, and Si
Engine Overheats or Leaks Coolant
(Supersedes 08-044, dated July 30, 2009, to revise the information marked by the black bars and asterisks)
REVISION SUMMARY
*Under PARTS INFORMATION, a flange bolt (14 x 130) was added, along with application information for an existing flange bolt (14x 115).*
SYMPTOM
The engine is leaking coolant and may be overheating.
PROBABLE CAUSE
The engine block is cracking at the coolant passages.
CORRECTIVE ACTION
Install a new engine block assembly.
REQUIRED MATERIALS
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Failed Part: P/N 10002-RNA-A00
H/C 8143323
Defect Code: 07601
Symptom Code: 09105
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
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. Pressure-test 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 2006-2009 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 4-29 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 6-27 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 6-32 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. M/T only: Remove the M/T from the engine:
^ Refer to page 13-89, beginning with step 31, of the service manual, or
^ Online, enter keywords TRANS REMOVAL, and select Manual Transmission Removal (5M/T) from the list.
7. A/T only: Remove the A/T from the engine:
^ Refer to page 14-223, beginning with step 7, of the service manual, or
^ Online, enter keywords TRANS REMOVAL, and select Automatic Transmission Removal (A/T) from the list.
8. Install the original cylinder head on the new short block:
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.
9. M/T only: Install the M/T onto the engine:
^ Refer to page 13-15 of the service manual, or
^ Online, enter keywords TRANS INSTALLATION, and select Manual Transmission Installation (5M/T) from the list.
10. A/T only: Install the A/T onto the engine:
^ Refer to page 14-234, beginning with step 4, of the service manual, or
^ Online, enter keywords TRANS INSTALLATION, select Automatic Transmission Installation (A/T) from the list, and begin at step 4.
11. 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 (R18A1 Engine) from the list.
NOTE:
To avoid electrical problems, make sure that the ground wire connection G101 (Photo 29 ETM) is clean and tight.
12. 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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