Service Bulletin

Service Bulletin
Applies To:
2009-13 Pilot – Check the iN VIN status for eligibility
13-082
August 30, 2014
Warranty Extension: MIL Comes On With DTCs P0301 Through P0304
(Supersedes 13-082, dated October 8, 2013, to revise the information marked by the black bars)
REVISION SUMMARY
• The layout was changed to one column for pages 1 through 3.
• Under PARTS INFORMATION, a spark plug number was added for 2012–13 model years.
• Under WARRANTY CLAIM INFORMATION, information was deleted because 2012–13 model year vehicles did
not need a software update.
BACKGROUND
American Honda is announcing a powertrain warranty extension as a result of a settlement of a class action
captioned, Soto et al .v. American Honda Motor Co., Inc., Case No. 3:12-cv-1377-SI (N.D. Cal.).
The piston rings on certain cylinders may rotate and align which can lead to spark plug fouling. This can set DTCs
P0301 through P0304 and cause the MIL to come on.
American Honda is extending the powertrain warranty to cover repairs related to engine misfire (that triggers DTCs
P0301 through P0304) to 8 years with unlimited mileage from the original date of purchase and has settled a class
action based on this remedial measure.
This 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 state’s law.
CUSTOMER NOTIFICATION
Owners of affected vehicles were sent a class action settlement notice regarding this warranty extension starting in
October 2013.
Before doing work on a vehicle, verify its eligibility by doing an iN VIN status inquiry.
Refer customers seeking information about settlement benefits to www.enginemisfiresettlement.com, or instruct
them to call 888-888-3082.
CORRECTIVE ACTION
Inspect the vehicle and, if necessary, clean the pistons, and replace the piston rings in the affected cylinders.
 2014 American Honda Motor Co., Inc. – All Rights Reserved
ATB 50102-51866 REV2 (1409)
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CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment,
and training to correctly and safely maintain your vehicle. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume
this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an
authorized Honda automobile dealer.
PARTS INFORMATION
NOTE: Do the DIAGNOSIS first to determine which cylinders you will need to repair.
Required Parts
Part Name
Part Number
Cyl. Gasket (Fr)
12251–R70–A01
Cyl. Gasket (Rr)
Cyl 1-3
Cyl 1-4
1
12261–R70–A01
1
1
Drain Washer 14 mm
94109–14000
1
1
EGR Pipe Gasket A
18716–R70–A01
1
1
EGR Pipe Gasket B
18719–R70–A01
1
1
Ex. Chamber Gasket
18115–R70–A01
1
2
Ex. Pipe Gasket
18212–SA7–003
2
2
Head Gasket Set
12030–R70–A00
Head Gasket Rr.
12050–R70–A00
1
1
1
In. Manifold Gasket
17146–R70–A01
1
1
In. Manifold Gasket
17105–RCJ–A01
1
1
Oil Filter
15400–PLM–A02
1
1
O-ring (7.47 mm x 3.6 mm)
91301–PLC–000
2
2
O-ring (31.2mm x4.1 mm)
91314–PH7–003
2
2
Piston Ring Set
13011–5G0–A02
3
4
Pre-chamber Gasket
18393–SDB–A00
1
1
Self-locking Nut (8 mm)
90212–RCA–A01
4
8
Self-locking Nut (10 mm)
90212–SA5–003
9
9
Spark Plug (2009–11)
12290-R70-A01
4
4
Spark Plug (2012–13)
12290-R71-L01
4
4
Strainer O-ring
15221–RYE–A01
1
1
Timing Belt Bolt
14551–RCA–A01
1
1
Water Gasket Fr.
19411–P8A–A03
1
1
Water Gasket Rr.
19412–P8A–A02
1
1
Replace Parts as Needed
Part Name
Connecting Rod Bolt
Head Cover Washer
Washer-Bolt (12 x 163)
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Part Number
13204–P8A–A01
90442–P8A–A00
90005–PAA–A01
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REQUIRED MATERIALS
Material Description
Honda Long-Life Antifreeze/Coolant Type 2
Genuine Honda Motor Oil 0W–20
Genuine Honda Motor Oil 5W–20 (if requested)
(2008-11)
Hondabond HT
Genuine Honda Throttle Plate Cleaner
Nylon Parts Cleaning Brush
5/16 ID Flexible Hose
Part Number
OL999–9011
08798–9036
08798–9032
Quantity
3 gallons
6 quarts
6 quarts
08718–0004
08700–9204
(commercially available)
(commercially available)
2 tubes
TOOL INFORMATION
Tool Description
Tool Number
Piston Ring Groove Cleaner
Gasket Remover/Pan Separator
07AAZ–TA5A100
LIL50190
Quantity
1
1
WARRANTY CLAIM INFORMATION
NOTE: The procedure in this bulletin is different than the service manual. This procedure does not require the
complete removal of the power steering pump, catalytic converter(s), engine and transmission, or the crankshaft.
As a result, the operation number is unique and the FRT is reduced.
OP#
Description
Flat Rate Time
Failed Part Number
1171G9
2009–11 Pilot: Procedure A
Update the PCM and replace spark plugs 1–4 (includes
diagnosis).
0.5 hr
13011–R70–A02
1171H0
2009–11 Pilot: Procedure B
Replace piston rings 1–3 and replace spark plugs 1–4 (includes
diagnosis).
9.1 hrs
13011–R70–A02
1171H0B 2009–11 Pilot: Add if replacing piston rings on cylinder 4.
1.9 hrs
1171H0
2012–13 Pilot:
Replace piston rings 1–3 and replace spark plugs 1–4 (includes
diagnosis).
9.1 hrs
13011–R70–A02
13011–5G0–A01
2012–13 Pilot: Add if replacing piston rings on cylinder 4.
1.9 hrs
13011–5G0–A01
1171H0B
Defect Code:
5V500
Symptom Code:
JC000
Skill Level:
Repair Technician
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DIAGNOSIS
1. Connect the HDS to the vehicle and check for the
following DTCs: P0301, P0302, P0303, P0304.
• If any of these DTCs are stored, go to step 2.
• If none of these DTCs are stored, this bulletin
does not apply. Continue with normal
troubleshooting.
2. Check the PCM software and note if it is earlier
than shown below, then go to step 3 (all 2012 and
2013 vehicles are up to date).
Program ID
(or later)
Program P/N
(or later)
2009–10 Pilot
(2WD)
N0A570
37805–RN0–A57
2009–10 Pilot
(4WD)
N0A770
37805–RN0–A77
2011 Pilot (2WD)
N0A630
37805–RN0–A63
2011 Pilot (4WD)
N0A830
37805–RN0–A83
Year/Model
3. Remove and check the spark plug(s) on the
affected cylinders (example: if P0301 is stored,
check the spark plug on cylinder No. 1).
• If the spark plug(s) are not fouled, this bulletin
does not apply. Continue with normal
troubleshooting.
• If this vehicle has any of the above DTCs, the
spark plug(s) are fouled, and the software is an
earlier version, go to REPAIR PROCEDURE A.
• If this vehicle has any of the above DTCs, the
spark plug(s) are fouled, and the software is a
current or later version, go to step 4.
NOTE: Below are examples of good and fouled
spark plugs.
GOOD
NO GOOD
4. Note which DTCs are stored in the vehicle.
• If the vehicle has one or more of the following
stored DTCs: P0301, P0302, P0303, go to
REPAIR PROCEDURE B to clean the pistons,
replace the piston rings on the cylinders 1–3, and
replace the spark plugs on cylinders 1–4.
• If the vehicle has DTC P0304 with or without any
of the other three DTCs stored, go to REPAIR
PROCEDURE B to clean the pistons, replace the
piston rings on cylinders 1–4, and replace the
spark plugs on cylinders 1–4.
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REPAIR PROCEDURE A
1. Update the PCM software. Refer to Service Bulletin
01-023, Updating Control Units/Modules.
3. Remove the intake duct.
CLIPS
2. Replace spark plugs on cylinders 1–4, then return
the vehicle to the customer.
REPAIR PROCEDURE B
The following service manual procedures have been
used in full or in part within this service bulletin. For
more detail on these procedures, and torque
specifications for some components, refer to the
appropriate electronic service manual.
• Battery Terminal Disconnection and Reconnection
• Fuel Pressure Relieving
• Fuel Line/Quick-Connect Fitting Removal
• Air Cleaner Removal/Installation
• Splash Shield Replacement
• Drive Belt Removal/Installation
• Engine Oil Replacement
• Coolant Replacement
• Hydraulic Power Steering Fluid Check/Replacement
• Intake Manifold Removal and Installation
• Timing Belt Removal and Installation
• Warm Up TWC Removal/Installation
• Cylinder Head Cover Removal
• Cylinder Head Removal and Installation
• Piston Ring Replacement
• PCM Idle Learn Procedure
Engine Repair
• Use fender covers to avoid damaging painted
surfaces.
• To avoid damaging any wires and terminals, unplug
the circuit connectors carefully while holding the
connector portion.
• Mark all the circuits and hoses to avoid
misconnection. Make sure they do not contact other
circuit wiring, hoses, or interfere with other parts.
AIR INTAKE DUCT
4. Do the battery removal procedure.
5. Disconnect the fuel feed hose line at the bulkhead.
QUICK-CONNECT
FITTING COVER
COVER
NUTS (2)
9.8 N.m
(7.2 lb-ft)
1. Relieve the fuel pressure.
2. Remove both front wheels so you can fully lower
the vehicle.
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6. Remove the engine cover.
12. Install a 5/16th inner diameter rubber hose on the
drain bolt located at the rear of the engine block,
loosen the drain bolt, and drain all remaining
coolant. Then disconnect the oil pressure switch
connector.
ENGINE COVER
OIL PRESSURE
SWITCH
7. Remove the radiator cap.
RUBBER
HOSE
8. Raise the vehicle.
DRAIN BOLT
10 N.m (7.4 lb-ft)
9. Remove the front splash shield.
13. Remove the subframe stiffener.
FRONT SPLASH SHIELD
10. Drain the engine oil.
BOLT
11. Loosen the drain plug on the radiator, and drain the
coolant.
10 x 1.25 mm
59 N.m (43 lb-ft)
Replace.
DRAIN
PLUG
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14. Remove exhaust pipe A.
19. Disconnect the MAP sensor connector and the
breather pipe, then remove the intake air duct.
GASKETS
Replace.
INTAKE
AIR DUCT
GASKETS
Replace.
EXHAUST
PIPE A
BREATHER
PIPE
SELF-LOCKING NUTS
54 N.m (40 lb-ft)
Replace.
SELF-LOCKING NUTS
MAP SENSOR
CONNECTOR
33 N.m (25 lb-ft)
Replace.
15. Depending on the diagnosis, remove the
appropriate WU-TWC support bracket bolts.
16. Remove the EGR lower pipe nuts.
17. Remove the crankshaft pulley bolt but not the
pulley.
NOTE: Make sure to apply new oil to the bolt flange
and threads before reinstallation.
20. Disconnect the throttle body connector, the EVAP
canister purge valve connector, the EVAP hose,
the brake booster vacuum hose, and the vacuum
hose.
21. Disconnect and plug the water bypass hoses.
EVAP CANISTER
PURGE VALVE
CONNECTOR
BRAKE BOOSTER
VACUUM HOSE
: Remove any oil
: Clean
: Lubricate with new engine oil
CRANKSHAFT
PULLEY
PULLEY
PULLEY
WASHER
WATER
BYPASS
HOSES
EVAP HOSE
THROTTLE BODY
CONNECTOR
BOLT
22. Remove the drive belt.
18. Lower the vehicle.
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23. Remove the drive belt auto-tensioner.
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24. Remove the power steering pump bolts, power
steering hose bracket, then secure the power
steering pump out of the way.
NOTE: Do not remove any of the hoses.
9.8 N.m
(7.2 lb-ft)
POWER STEERING
HOSE BRACKET
31. Remove the intake manifold bolts and nuts in three
steps, then remove the intake manifold.
SPECIFIED TORQUE
22 N.m (16 lb-ft)
3
1
5
POWER
STEERING
PUMP
7
9
8
6
4
2
32. Remove the PCM cover and connectors.
Disconnect the battery cables from the underhood
fuse box.
ECM/PCM
COVER
ECM/PCM
22 N.m (16 lb-ft)
25. Remove the engine harness holder bolt on the side
engine mount.
26. Set the engine to TDC cylinder one.
27. Remove the crankshaft pulley.
28. Remove the timing belt.
29. Remove the timing belt idler pulley.
30. Remove the engine intake upper cover bolts and
nuts, then remove the cover and PCV hose.
BOLTS (3)
9.8 N.m (7.2 lb-ft)
SPECIFIED TORQUE
6 x 1.0 mm
12 N.m (8.7 lb-ft)
2
6
UPPER
COVER
4
8
10
12
11
7
9
3
5
1
PCV HOSE
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33. Remove the appropriate ignition coils based on the
diagnosis.
NOTE: Depending on the diagnosis, you will either
have to remove the rear bank ignition coils or both
ignition coil banks.
FRONT
SPARK PLUGS
22 N.m (16 lb-ft)
6 x 1.0 mm
12 N.m
(8.7 lb-ft)
IGNITION COILS
IGNITION COIL
CONNECTOR
REAR
IGNITION
COILS
SPARK PLUGS
22 N.m (16 lb-ft)
34. Depending on the diagnosis, remove some or all of
the following:
• ECT sensor connector
• Front rocker arm oil pressure switch connector
• Rear rocker arm oil pressure switch connector
• CMP sensor connector
• Front A/F sensor one connector
• Rear A/F sensor one connector
• Front secondary HO2S connector
• Rear secondary HO2S connector
• Rocker arm oil control solenoid A connector
(bank one)
• Rocker arm oil control solenoid A connector
(bank two)
• Rocker arm oil control solenoid B connector
(bank one)
• Alternator connector and positive alternator cable
• A/C clutch switch connector
• EGR 5P valve connector
• Engine ground
• Knock sensor
• Fuel injector connectors and clips
35. Remove the quick-connect fitting cover, then
disconnect the fuel feed hose.
QUICK-CONNECT
FITTING COVER
6 x 1.0 mm
12 N.m
(8.7 lb-ft)
IGNITION COIL
CONNECTOR
FUEL FEED HOSE
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36. Remove the EVAP canister purge joint with the
bracket.
39. Separate the water passage from the heads.
GASKETS
Replace.
22 N.m
(16 lb-ft)
EVAP CANISTER
PURGE JOINT
WATER PASSAGE
CONNECTING
PIPE
12 N.m (8.7 lb-ft)
37. Remove the fuel rail connecting joint hose.
MOUNTING BOLT
22 N.m (16 lb-ft)
O-RING
Replace.
O-RING
Replace.
40. Remove the appropriate WU-TWC, depending on
diagnosis.
NOTE: Set the WU-TWC aside and cover the
opening with shop towels to prevent coolant from
entering.
FRONT
GASKET
Replace.
QUICK-CONNECT
FITTING
FRONT
WU-TWC
38. Remove the EGR pipe mounting bolts, then
remove the EGR pipe.
NUTS
31 N.m
(23 lb-ft)
Replace.
GASKET
Replace.
GASKET
Replace.
EGR
PIPE
REAR
GASKET
MOUNTING
BOLTS
22 N.m
(16 lb-ft)
Replace.
REAR
WU-TWC
NUTS
31 N.m
(23 lb-ft)
Replace.
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41. Remove the appropriate head with the injector
base attached.
NOTE: Depending on diagnosis, you will remove
the rear bank head or both heads.
FRONT
5
3
7
1
NOTE: Below are the head bolt torque
specifications for reinstallation.
• First step: torque the cylinder bolts in sequence
to 29 N•m (22 lb-ft).
• Second step: tighten in sequence an additional
90 degrees.
• Third step: tighten in sequence an additional
90 degrees.
• If the bolts are new, tighten an additional
90 degrees.
FIRST STEP
8
2
6
4
REAR
5
SECOND STEP
THIRD STEP
3
7
1
(Newbolt)
43. Raise the vehicle.
44. Remove the CKP sensor cover and bolts, then
disconnect the CKP sensor connector.
BOLT
8
2
6
4
12 N.m
(8.7 lb-ft)
42. Measure the head bolts to determine if they need
replacement. If either diameter is less than
11.3 mm (0.445 in), replace the cylinder head bolt.
50 mm (1.97 in)
45 mm (1.77 in)
B
A
CKP SENSOR
CONNECTOR
12 N.m (8.7 lb-ft)
13-082
CKP SENSOR
COVER
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45. Remove the torque converter case cover and the
four bolts securing the oil pan to the transmission.
47. Using a flat blade screwdriver, separate the oil pan
from the engine block in the areas shown.
BOLTS (4)
74 N.m (54 lb-ft)
12 N.m
(8.7 lb-ft)
TORQUE
CONVERTER
CASE COVER
48. Remove the oil strainer and baffle plate.
46. Remove all bolts securing the oil pan.
12 N.m
(8.7 lb-ft)
BOLTS
12 N.m (8.7 lb-ft)
9
5
1
3
7
OIL
STRAINER
12 N.m
(8.7 lb-ft)
11
O-RING
Replace.
BAFFLE
PLATE
13
15
16
17
18
12
14
10
6
2
4
8
49. Remove the appropriate pistons depending on
diagnosis, then go to PISTON CLEANING
PROCEDURE.
NOTE: When removing the piston rod caps, be
sure to keep all caps and bolts with their
corresponding pistons for reassembly purposes.
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PISTON CLEANING PROCEDURE
1. Remove the piston rings from the piston using a
ring expander. Be careful not to damage the piston.
4. Press the handle on the piston ring groove cleaner
tool and slide the cleaning bit onto the appropriate
piston ring grooves.
OLD PISTON
RINGS
RING
EXPANDER
2. Spray the piston head and piston ring grooves
thoroughly with Honda throttle plate cleaner.
3. While holding the piston upright in your left hand,
take the piston ring groove cleaner tool in your right
hand and line up the cleaner tool guides with the
second (middle) piston ring groove.
13-082
5. Once the cleaning bit is in the appropriate ring
grooves of the piston, make sure the tool handle
clicks in to place.
NOTE: There is only one notch on the tool for the
handle to engage.
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6. Hold the piston steady and rotate the tool
counter-clockwise five to six times to remove any
carbon deposits in the piston ring grooves.
Do not rotate the tool clockwise.
NOTE: You can watch this procedure in the
Tech2Tech segment “How to Clean Piston Ring
Grooves”.
NOTE: Below are some examples of before and
after pictures. Depending on mileage and running
conditions, the pistons will achieve different levels
of cleanliness.
7. Remove the piston groove cleaning tool and clean
off the carbon from the tool bit.
8. Finish cleaning the piston with throttle plate cleaner
and the nylon brush. Do not use a steel wire brush.
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9. Install the piston rings as shown.
NOTE: The first (top) ring has a 1D manufacturing
mark and the second (middle) ring has an SPR
manufacturing mark. The manufacturing marks
must be facing upward.
12. Install the piston/connecting rod assembly in to the
cylinder bore with the arrow on top of the piston
facing the timing belt side of the engine.
NOTE: Be careful not to damage the cylinder wall
when installing the piston.
ARROW
TOP RING
MANUFACTURING
MARKS
MANUFACTURING
MARKS
SECOND
RING
13. Measure the diameter of the connecting rod bolts to
determine if they need replacement. Calculate the
difference in diameter between point A and point B.
It should not be more than 0–0.1 mm (0–0.004 in).
35 mm (1.38 in)
B
A
20 mm (0.79 in)
10. Position the ring end gaps as shown.
NOTE: If the ring gaps are not positioned correctly,
excessive blowby may occur.
OIL RING GAP
About 90°
SECOND RING GAP
About 45°
TOP RING GAP and
SPACER RING GAP
OIL RING GAP
PISTON PIN
11. Apply new engine oil to the piston, the inside of the
piston ring compressor, and the cylinder bore.
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14. Apply new oil to the connecting rod bolt threads
and flanges. Torque the bolts to 20 N•m (14 lb-ft),
then tighten the connecting rod bolts an additional
90 degrees.
After torquing, turn bolt
another quarter turn.
CONNECTING
ROD MARK
BOLTS
20 N.m
(14 lb-ft)
CONNECTING
ROD
ROD CAP
CONNECTING
ROD BEARING
15. Reinstall the remaining components in the reverse
order of removal.
16. Replace spark plugs 1–4.
17. Replace the oil filter and refill all fluids.
18. Do the idle learn procedure.
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