Campaign - Valve Spring Seats May Be Missing
09-035May 23, 2009
Applies To:
2009 Civic 2-Door - From VIN 2HGFG1...9H53931 6 thru 2HGFG1...9H539598 2009 Civic 4-Door - From VIN 2HGFA1...9H360407 thru 2HGFA1...9H525717
Product Update: Valve Spring Seats May Be Missing
BACKGROUND
During engine assembly, a few cylinder heads were assembled without one or more of the valve spring seats. Without a spring seat, the valve spring would damage the cylinder head, and the valve would eventually fail.
VEHICLES AFFECTED
Within the VIN ranges above, only 596 vehicles are potentially affected. These vehicles were built in Canada during 3 to 5 days in mid-May, 2009. Many of the potentially affected vehicles are being repaired before they reach the dealerships. None of the potentially affected vehicles have been sold. To verify vehicle eligibility, you must do a VIN status inquiry.
To see if a vehicle has already had this campaign completed, check for a punch mark below the first character of the engine compartment VIN.
A few vehicles affected by this campaign may be in your new vehicle inventory. These vehicles cannot be sold or leased until they are inspected and, if needed, repaired. Should an unrepaired vehicle cause an injury or damage because of the campaigned item, the dealership will be solely responsible to the damaged party, and will be required to defend and indemnify American Honda for any resulting claims. To see if a vehicle is affected by this campaign, do a VIN status inquiry before selling or leasing it.
CORRECTIVE ACTION
Inspect the cylinder head for missing valve spring seats. If any seats are missing, disassemble the affected valve(s), and install a new spring seat, a new stem seal, and a new valve spring.
PARTS INFORMATION
TOOL INFORMATION
Valve Cotter Remover/Installer:
Snap-on P/N GA318A, or equivalent
14 mm Cylinder Leakdown Adapter:
Snap-on P/N MT26J200R, or equivalent
Valve Stem Seal Pliers:
Snap-on P/N YA6290, or equivalent
Valve Stem Seal Driver:
Honda Special Tool, T/N 07PAD-0010000
WARRANTY CLAIM INFORMATION
Failed Part: P/N 14775-P08-000
H/C 3875325
Defect Code: 5V500
Symptom Code: R0900
Skill Level: Repair Technician
INSPECTION PROCEDURE
1. Carefully remove the center cowl cover using a trim tool (9 clips):
^ Refer to step 2 on page 20-238 of the 2006-2009 Civic Service Manual or
^ Online, enter keyword COWL, select Cowl Cover Replacement from the list, and do step 2 of the procedure.
2. Remove the under-cowl panel (9 bolts):
^ Refer to step 4 on page 20-238 of the service manual, or
^ Online, enter keyword COWL, select Cowl Cover Replacement from the list, and do step 4 of the procedure.
3. Remove the cylinder head cover:
^ Refer to page 6-24 of the service manual, or
^ Online, enter keywords CYL COVER, and select Cylinder Head Cover Removal (R18A1 and R18A4 Engine) from the list.
4. Remove the right front wheel to gain access to the crankshaft pulley bolt.
5. Attach a socket with a long extension and a ratchet to the crankshaft pulley bolt, then turn the engine clockwise, by hand, until cylinder 1 is at TDC.
6. Check for valve spring movement at each of the four valves in cylinder 1. Push against the base of each valve spring with a flat-tip screwdriver, and watch the sideways movement of the valve spring:
^ If the spring moves about 1 or 2 mm, the valve spring seat is installed.
^ If the spring moves significantly more than 2 mm, the valve spring seat is not installed. Mark the edge of the cylinder head next to that valve with a permanent marker.
7. Repeat steps 5 and 6 on the remaining cylinders:
^ If the sideways movement of all 16 valve springs is about 1 or 2 mm, all the valve spring seats are installed. Go to step 8.
^ If any of the valve springs moved significantly more than 2 mm, go to REPAIR PROCEDURE.
8. Reinstall the cylinder head cover:
^ Refer to page 6-25 of the service manual, or
^ Online, enter keywords CYL COVER, and select Cylinder Head Cover Installation (R18A1 and R18A4 Engine) from the list.
9. Reinstall the under-cowl panel:
^ Torque the four 8 x 1.25 mm bolts to 22 N.m (16 lb-ft).
^ Torque the five 6 x 1.0 mm bolts to 9.8 N.m (7.2 lb-ft).
10. Reinstall the center cowl cover, and replace any damaged clips.
11. Remove the tools from the crankshaft pulley bolt, and reinstall the right front wheel.
12. Center-punch a completion mark below the first character of the engine compartment VIN:
^ Slide open the FRAME NUMBER door on the center cowl cover.
^ Use a long punch to reach the VIN.
REPAIR PROCEDURE
1. Remove the rocker arm assembly:
^ Refer to page 6-33 of the service manual, or
^ Online, enter keywords ROCKER REM, and select Rocker Arm Assembly Removal (R18A1 and R18A4 Engine) from the list.
NOTE:
To keep each rocker arm in its correct position, hold them with rubber bands before you remove the rocker arm assembly (see below).
2. Using the socket attached to the crankshaft pulley bolt, turn the engine clockwise, by hand, until the affected cylinder is at BDC (bottom-dead-center).
3. Remove the coil and the spark plug from the affected cylinder.
4. Screw the 14 mm cylinder leakdown adapter into the spark plug hole. Attach the adapter to an air regulator, attach the regulator to shop air, and slowly apply 125 psi of air. (This keeps the valves pressed against their seats inside the cylinder.)
5. Remove the installation adapter from the valve cotter remover/installer tool, and place the end of the tool on top of the affected valve. Push down on the tool to compress the valve spring. When you release the tool, the valve cotters should stay inside the end of the tool. If needed, repeat this step until the cotters are removed.
6. Remove the valve spring retainer and the spring, then remove the valve stem seal with stem seal remover pliers. The valve spring and the stem seal will not be reused.
7. Place a new valve spring seat over the valve. then install a new stem seal with the stem seal driver.
NOTE:
Valve stem seals are different between the intake and exhaust sides. Make sure you install the correct seal.
8. Place a new spring over the valve, insert the valve cotters into the spring retainer, and place the retainer on the valve spring.
NOTE:
New intake valve springs have a violet color on them. New exhaust valve springs have a gray color on them.
9. Attach the installation adapter to the valve cotter remover/installer tool, and place the end of the tool on top of the affected valve. Push down on the tool to compress the valve spring. When you release the tool, the valve cotters should be reinstalled. If needed, repeat this step until the cotters are reinstalled.
10. Set the rocker arm assembly back onto the cylinder head, and remove the rubber bands.
11. Reinstall the rocker arm assembly, and adjust the valve clearances:
^ Refer to page 6-47 of the service manual, or
^ Online, enter keywords ROCKER INSTALL, and select Rocker Arm Assembly Installation (R18A1 and R18A4 Engine) from the list.
12. Reinstall the spark plug(s) and the coil(s).
13. Reinstall the cylinder head cover:
^ Refer to page 6-25 of the service manual, or
^ Online, enter keyword CYL COVER, and select Cylinder Head Cover Installation (R18A1 and R18A4 Engine) from the list.
14. Reinstall the under-cowl panel:
^ Torque the four 8 x 1.25 mm bolts to 22 N.m (16 lb-ft).
^ Torque the five 6 x 1.0 mm bolts to 9.8 N.m (7.2 lb-ft).
15. Reinstall the center cowl cover, and replace any damaged clips.
16. Remove the tools from the crankshaft pulley bolt, and reinstall the right front wheel.
17. Center-punch a completion mark below the first character of the engine compartment VIN:
^ Slide open the FRAME NUMBER door on the center cowl cover.
^ Use a long punch to reach the VIN.
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