Engine - Coolant Leak From Engine Block
01-037April 15, 2002
Applies To:
1999 2.3CL ALL
Coolant Leak From the Engine Block
(Supersedes 01-037, dated October 22, 2001)
** Indicates updated information **
SYMPTOM
Coolant is leaking where the connecting pipe fits into the engine block.
PROBABLE CAUSE
The 0-ring groove diameter of the connecting pipe is too small. This, together with accumulated road grime, can cause coolant to seep past the 0-ring. This problem is especially common in areas of the U.S. where the roads are treated for a buildup of snow and ice.
CORRECTIVE ACTION
Look for a coolant trail where the connecting pipe fits into the engine block. Replace the connecting pipe and both 0-rings if you see a coolant trail.
PARTS INFORMATION
Connecting Pipe:
P/N 19505-PAA-A00
0-Ring (two required for connecting pipe):
P/N 91314-PH7-003
Gasket (0-Ring) (one required for thermostat housing):
P/N 91312-P0A-000 Oil Filter:
P/N 15400-P0H-305
REQUIRED MATERIALS
Honda All Season Antifreeze/Coolant Type 2 (1 quart):
** P/N 0L999-9002**
5W-20 Engine Oil (1 quart):
P/N 08798-9023
3M Scotch-Brite General Purpose Pad-Maroon:
(Commercially available. 3M color-codes these pads to denote specific uses. You need the maroon-colored pad for this repair.)
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Operation Number: 114109
Flat Rate Time: 0.8 hour
Failed Part: P/N 19505-PAA-A00
Defect Code: 060
Contention Code: B06
Template ID: 01-037A
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
Raise the vehicle on a lift. Look for a coolant trail where the connecting pipe fits into the engine block.
^ If you see a coolant trail, go to REPAIR PROCEDURE.
^ If you do not see a coolant trail, look for other possible causes for the leak.
REPAIR PROCEDURE
1. Remove and discard the oil filter. (This lets you get at the connecting pipe.)
2. Drain the coolant from the system. Use a clean container to collect the coolant, since you will be reusing the coolant later.
3. Detach the heater outlet hose and the coolant bypass hose from the connecting pipe.
4. Remove the connecting pipe mounting bolt.
5. Remove the air intake duct.
6. Unplug the 2P connector from the engine coolant temperature (ECT) sensor on the thermostat housing. Remove the two thermostat housing mounting bolts, and gently pull the housing away from the connecting pipe. (You do not need to fully remove the thermostat housing.) Discard the 0-ring.
7. Remove and discard the connecting pipe and 0-rings.
8. Use a maroon-colored Scotch-Brite pad to clean the engine block opening for the connecting pipe.
9. Place a new 0-ring on each end of the new connecting pipe. Lubricate both 0-rings with engine oil to prevent damage during installation.
10. Slide the connecting pipe into the engine block opening, and loosely reinstall the mounting bolt.
11. Position the new 0-ring on the back of the thermostat housing, and slide the connecting pipe into the housing, being careful not to damage either 0-ring.
12. Reinstall the thermostat housing mounting bolts. Torque the bolts to 22 N.m (16 lb-ft). Plug the 2P connector into the ECT sensor.
13. Reinstall the air intake duct.
14. Make sure the connecting pipe is properly installed and seated. Torque the mounting bolt to 22 N.m (16 lb-ft). Attach the heater outlet hose and the coolant bypass hose.
15. Install a new oil filter. (Do not reuse the old filter. The old gasket on the filter may not seal properly, causing oil leakage and possible engine failure.)
16. Refill the cooling system with the coolant you saved in step 2. Make sure you check for the correct protection level. If you need to add coolant, use only Honda All Season Antifreeze/Coolant Type 2.
17. Start the engine, and bleed the cooling system (see section 10 of the 1999 2.3CL Service Manual). Make sure the heater control is set to MAX heat. Let the cooling fan cycle on and off several times.
18. Turn off the engine, and check the engine oil level. Add 5W-20 engine oil as needed.
DISCLAIMER