Campaign - Engine Rocker Shaft Holder Insp./Replacement: Overview
10-072December 3, 2010
Applies To:
See VEHICLES AFFECTED
Product Update: Engine Oil May Leak From Rear of Cylinder Head Cover
BACKGROUND
A manufacturing problem with the No.5 rocker shaft holder may cause an engine oil leak at the rear of the cylinder head cover.
VEHICLES AFFECTED
Not all vehicles within the affected VIN ranges have a problem with the No.5 rocker shaft holder; most potentially affected vehicles require only an inspection.
To verify vehicle eligibility, check for at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown as eligible on an iN 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 the vehicle has already been inspected and, if needed, repaired.
Some of the vehicles affected by this product update may be in your new vehicle inventory. These vehicles must be updated before they are sold or leased. To see if a vehicle is affected by this campaign, do a VIN status inquiry before selling it, leasing it, or returning it to a service customer.
Should an unrepaired vehicle that was in inventory, or that came in for service after this service bulletin was issued, cause an injury or property 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.
CUSTOMER NOTIFICATION
All owners of affected vehicles will be sent a notification of this product update. An example of the customer notification is at the end of this service bulletin.
CORRECTIVE ACTION
Inspect the No.5 rocker shaft holder. If the holder was made during the specific dates and shifts described under INSPECTION, replace the cam/rocker shaft holder set.
PARTS INFORMATION
Cam/Rocker Shaft Holder Set: P/N 12245-R40-A00
REQUIRED MATERIALS
Hondabond HT Liquid Silicone Gasket:
P/N 08718-0004
(One tube repairs about two vehicles.)
WARRANTY CLAIM INFORMATION
Failed Part: P/N 12100-R40-A02
Defect Code: 5RY00
Symptom Code: R5600
Skill Level: Repair Technician
INSPECTION PROCEDURE
NOTE:
^ Most potentially affected vehicles require only an inspection.
^ If you need more details on the items listed below, bookmark them in the appropriate service manual, or view them online:
- Cylinder Head Cover Removal
- Front Splash Shield Replacement
- Valve Clearance Adjustment
- Cylinder Head Cover Installation
1. Remove the cylinder head cover.
2. Visually inspect the center bridge on the No. 5 cam/rocker shaft holder:
^ If the center bridge has no casting marks or just one casting mark, the No. 5 rocker shaft holder is OK. Reinstall the cylinder head cover, then go to step 3.
^ If you see two casting marks on the center bridge, go to step 4.
3. Center-punch a completion mark above the first character of the engine compartment VIN.
4. Raise the vehicle on a lift, then remove the right front wheel.
5. Remove the front splash shield to access the crankshaft pulley.
6. Remove the camshaft auto-tensioner (chain case) cover.
7. Rotate the crankshaft clockwise to top dead center (TDC) on the No.1 cylinder. Make sure both camshaft and crankshaft TDC marks are in correct alignment.
8. Rotate the crankshaft counterclockwise to compress the auto-tensioner, then align the hole in the lock and the auto-tensioner, and insert a reusable lock pin.
9. Rotate the crankshaft clockwise to TDC on the No.1 cylinder. Make sure both camshaft and crankshaft TDC marks are in correct alignment.
10. Lower the vehicle.
11. Mark the camshaft chain at the punch marks on the exhaust camshaft sprocket and the VTC actuator.
12. Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.
NOTE:
Bolt # 1 is not on all engines.
13. Remove the five camshaft holders.
14. Carefully tip up the end of the intake camshaft until there is enough slack in the chain to lift the chain off the VTC actuator gear. Remove the intake camshaft.
15. Carefully tip up the end of the exhaust camshaft until there is enough slack in the chain to lift the chain off the exhaust camshaft sprocket. Remove the exhaust camshaft.
16. Bundle the rocker arms with rubber bands to keep them together as a set.
NOTE:
Use thick rubber bands (1/4 in. wide x 4 in. long, for example) to keep the locking pins from popping out of the rocker arm assembly.
17. Remove the rocker arm assembly:
^ Insert four of the camshaft holder bolts into the rocker shaft holders.
^ Using a flat-tip screwdriver, gently pry the front side of the No.5 rocker shaft holder side-to-side, then gently pry the front side of the No. 4, 3, 2, and 1 holders. Once the front side of each holder is loose (raised off its dowels), the back side will come off.
^ Lift the rocker arm assembly off the cylinder head.
18. Place the rocker arm assembly upside-down on your workbench.
19. On the bottom of the No. 5 rocker shaft holder, look for a small circle with numbers and dots stamped in it. These numbers and dots indicate the date and the shift when the holder was made. Here's how to decipher the numbers and the dots:
^ Top Number = Month (1-12)
^ Bottom Number = Day (1-31)
^ One Dot = 1st Shift
^ Two Dots = 2nd Shift
^ No Dots = 3rd Shift
Only those holders produced during these dates/shifts are affected:
^ October 5: Shift 2
^ October 6: Shifts 1, 2, and 3
^ October 7: Shifts 1, 2, and 3
^ October 8: Shifts 1 and 3
- If the date/shift code matches one of those listed above, the cam/rocker shaft holders must be replaced as a set. Go to REPAIR PROCEDURE.
- If the date/shift code does not match one of those listed above, the No.5 cam/rocker shaft holder is OK. Go to step 20.
UNDERSIDE OF ROCKER ARM ASSEMBLY
20. Clean and dry the No.5 rocker shaft holder mating surface.
21. Evenly apply a 2.5 mm (0.098 in) diameter bead of liquid gasket (P/N 08718-0004) to the cylinder head mating surface of the No. 5 rocker shaft holder, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.
22. Install the lost motion assembly in the cylinder head.
23. Insert the bolts into the rocker shaft holders, then install the rocker arm assembly on the cylinder head. Remove the rubber bands from the rocker arm assembly.
24. Remove the bolts from the rocker shaft holder.
25. Slide the exhaust camshaft in at an angle so the chain can slip over the exhaust camshaft gear.
26. Slide the intake camshaft in at an angle so the chain can slip over the VTC actuator.
27. Line up the marks you made on the chain with the punch marks on the exhaust camshaft sprocket and the VTC actuator.
28. Apply engine oil to the camshaft journals and the camshaft holders, then reinstall the holders.
NOTE:
If you installed new rocker shaft holders, install new camshaft holders.
29. Torque the camshaft holders, starting in the middle and working your way outward in the numbered sequence.
30. Remove the lock pin from the auto-tensioner.
31. Rotate the crankshaft in the direction of engine rotation (clockwise) two full turns, then stop at the white TDC mark. Make sure the camshafts line up as shown in step 11.
NOTE:
Failure to properly time the camshafts to the crankshaft will cause DTC P0341, P0011, or P1009 to be stored.
32. Check the valve clearances, and adjust them if needed.
^ Intake Valves: 0.21 - 0.25 mm (0.008 - 0.010 in.)
^ Exhaust Valves: 0.25 - 0.29 mm (0.010 - 0.011 in.)
33. Reseal and reinstall the auto-tensioner (chain case) cover. Torque the cover bolts to 12 N.m (8.7 lb-ft).
34. Reinstall the cylinder head cover.
^ Torque the cylinder head cover bolts, the coil bolts, the coil cover bolts, the EVAP canister purge valve bracket bolts, and the engine cover bolts to 12 N.m (8.7 lb-ft.).
^ Accord only: Torque the strut brace nuts to 22 N.m (16 lb-ft.).
35. Raise the vehicle, then reinstall the front splash shield.
36. Reinstall the right front wheel.
37. Center-punch a completion mark above the first character of the engine compartment VIN.
REPAIR PROCEDURE
1. Disassemble the rocker arm assembly, using the illustration below for reference.
NOTE:
Identify the parts as they are removed; this will help you to correctly reassemble the rocker arm assembly.
2. Reassemble the rocker arm assembly using new rocker shaft holders.
NOTE:
Install the new rocker shaft holders in their properly numbered sequence (1, 2, 3, 4, 5).
3. To complete the repair, go to INSPECTION PROCEDURE, and do steps 20 thru 37.
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