Applies To: See VEHICLES AFFECTED

Service Bulletin

08-032

May 16, 2008

Product Update: Engine Makes a Clicking or a Tapping Noise

BACKGROUND

During engine assembly, an incorrect exhaust rocker arm shaft may have been installed. The incorrect shaft does not allow proper lubrication to the camshaft journals, which results in excessive heat buildup. In some cases, the camshaft holder bolts loosen, allowing the rocker arm shaft to move and causing a clicking or a tapping noise.

VEHICLES AFFECTED

2008 Civic Si:

2HGFG21568H700044

2HGFG21588H700045

2HGFG215X8H700046

2HGFG21518H700047

2HGFG21538H700048

2HGFG21558H700049

2HGFG21538H700051

2HGFG21558H700052

2HGFG21578H700053

2HGFG21528H700056

2HGFG21568H700058

2HGFG21588H700059

2HGFG21548H700060

2HGFG21568H700061

2HGFG21588H700062

2HGFG215X8H700063

2HGFG21518H700064

2HGFG21558H700066

2HGFG21578H700067

2HGFG21598H700068

2HGFG21508H700069

2HGFG21578H700070

2HGFG21508H700072

2HGFG21528H700073

CUSTOMER NOTIFICATION

All owners of affected vehicles will be mailed a notification of this product update. An example of the customer notification is at the end of this service bulletin.

Before beginning work on a vehicle, verify its eligibility by checking at least one of these items:

• The customer has a notification letter.

• The vehicle is shown as eligible on a 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 this product update has already been completed.

CORRECTIVE ACTION

Replace the cylinder head assembly.

NOTE: The loss of lubrication is only in the camshaft and rocker arm area. There is no need to replace the short block assembly.

PARTS INFORMATION

Cylinder Head Assembly:

P/N 10003-RRB-A02, H/C 8600066

Cylinder Head Gasket Kit:

P/N 06110-RRB-A01, H/C 8352189

Coolant Separator:

P/N 11103-RAC-003, H/C 8144735

Retainer (Green):

P/N 17711-S0X-A31, H/C 5928288

REQUIRED MATERIALS

Hondabond HT:

P/N 08718-0001, H/C 2963817

(One Hondabond HT tube repairs about 10 vehicles.)

5W-20 Motor Oil (Quart Bottle):

P/N 08798-9023, H/C 6512610

(Each repair requires 4.4 quarts.)

© 2008 American Honda Motor Co., Inc. – All Rights Reserved ATB 39471 (0805)

1 of 3

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.

WARRANTY CLAIM INFORMATION

Operation Number: 1101T7

Flat Rate Time: 9.0 hours

Failed Part: P/N 10003-RRB-A02

H/C 8600066

Defect Code:

Symptom Code:

Template ID:

Skill Level:

5RS00

Q8300

08-032A

Repair Technician

INSPECTION PROCEDURE

1. Remove the cylinder head cover:

• Refer to page 6-85 of the 2006–2008 Civic

Service Manual, or

• Online, enter keywords HEAD COV, and select

Cylinder Head Cover Removal (K20Z3

Engine) from the list.

2. Inspect the exhaust rocker arm shaft through the slots in all four rockers arms as shown. You should see that the rocker arm shaft is solid inside all of the slots.

NOTE: If you cannot clearly see into the slots in the rocker arm, use a pick tool to feel for the rocker arm shaft.

GOOD

The shaft can be seen through this slot.

2 of 3

NO GOOD

The slot is empty.

• If the rocker arm shaft is not solid at any of the rocker arm slots, go to REPAIR PROCEDURE.

• It the rocker arm shaft is solid inside all of the slots, go to step 4 of REPAIR PROCEDURE.

08-032

REPAIR PROCEDURE

1. Remove the cylinder head:

• Refer to page 6-87 of the service manual, or

• Online, enter keywords CYL REM, and select

Cylinder Head Removal (K20Z3 Engine) from the list.

2. Install the new cylinder head assembly:

• Refer to page 6-106 of the service manual, or

• Online, enter keywords CYL INSTALL, and select Cylinder Head Installation (K20Z3

Engine) from the list.

3. Replace the engine oil (4.4 qt).

4. Center-punch a completion mark above the first character of the engine compartment VIN.

Center-punch here.

2HGFG2XXXXXXXXXXX

Example of Customer Letter

Spring 2008

Product Update: Engine Makes a Clicking or a

Tapping Noise

Dear 2008 Civic Si Owner:

This notice has been sent to inform you of an update that may be needed for your vehicle.

What is the problem?

During engine assembly, an incorrect rocker arm shaft may have been installed. The incorrect shaft does not allow proper lubrication to the camshaft journals, which results in excessive heat buildup. In some cases, the camshaft holder bolts loosen, allowing the rocker arm shaft to move and causing a clicking or a tapping noise.

What you should do.

Call any Honda dealer, and make an appointment to have your vehicle updated. The dealer will inspect the rocker shaft and, if needed, replace the complete head assembly, free of charge. Please plan to leave your vehicle at the dealership for at least a day to allow some flexibility in scheduling.

What to do if you feel this notice is in error.

Our records show that you are the current owner or lessee of a 2008 Civic Si involved in this product update. If this is not the case, or the name/address information is incorrect, please fill out and return the included, postage-paid information change card. We will then update our records.

If you have questions.

If you have questions about this product update, or need assistance with contacting a Honda dealer, please call

Honda Automobile Customer Service at (800) 999-1009.

We apologize for any inconvenience this product update may cause you.

Sincerely,

American Honda Motor Co., Inc.

Honda Automobile Division

08-032 3 of 3

May 16, 2008

Dear Service Manager:

Honda Motor Co., Ltd., is announcing a product update campaign for a small quantity of 2008

Civic Si vehicles.

During engine assembly, an incorrect rocker arm shaft may have been installed. The incorrect shaft does not allow proper lubrication to the camshafts, which results in excessive heat buildup. In some cases, the camshaft holder bolts loosen, allowing the rocker arm shaft to move and causing a clicking or a tapping noise. Only 30 vehicles are affected, and six of them have already been repaired.

Repair Strategy

The repair is to inspect the rocker arm shaft and, if the engine has the wrong rocker arm shaft installed, replace the complete cylinder head assembly. For repair, affected VIN, and warranty information, refer to Service Bulletin 08-032, Product Update: Engine Makes a

Clicking or a Tapping Noise.

Customer Notification

Customers will be sent a notification of this campaign the week of May 19. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items:

• The customer has a notification letter.

• The vehicle is shown as eligible on a VIN status inquiry.

Some vehicles affected by this product update may be in your used vehicle inventory. These vehicles should be updated before they are sold or leased. To see if a vehicle is affected, do a VIN status inquiry.

Parts Information

The complete cylinder head assemblies and related parts required for the repair are available through normal parts ordering channels.

Sincerely,

American Honda Motor Co., Inc.

Honda Automobile Division