Honda CIVIC 3D - User Manual

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Summary

Rear Damper Noise Diagnosis and Repair

Symptom Description

Details the audible symptoms of rear suspension noise when the vehicle is first driven.

Root Cause of Noise

Explains the mechanical friction leading to knock or squeak noise from dampers.

Countermeasure and Production Changes

Describes production modifications and aftersales repair strategy for damper noise.

Repair Procedure Steps

Guidance on preparing the jig, priming, and inserting it for lubricant application.

Lubricant Application and Final Steps

Lubricant Application

Details applying lubricant bursts and rotating the jig for treatment.

Procedure Completion and Verification

Covers repeating for the other damper, lowering vehicle, and road testing.

Cleaning and Lubricant Usage Notes

Instructions for cleaning the jig and notes on BG HCF grease usage.

Service Bulletin Details and Warranty

Claim and Operation Information

Provides claim code, symptom code, and operation number for the repair.

Parts Information

Lists part numbers for damper grease and applicator jig, and kit discontinuation.

Warranty Information

Specifies application as normal warranty and causal part for VIN lookup.

Summary

Rear Damper Noise Diagnosis and Repair

Symptom Description

Details the audible symptoms of rear suspension noise when the vehicle is first driven.

Root Cause of Noise

Explains the mechanical friction leading to knock or squeak noise from dampers.

Countermeasure and Production Changes

Describes production modifications and aftersales repair strategy for damper noise.

Repair Procedure Steps

Guidance on preparing the jig, priming, and inserting it for lubricant application.

Lubricant Application and Final Steps

Lubricant Application

Details applying lubricant bursts and rotating the jig for treatment.

Procedure Completion and Verification

Covers repeating for the other damper, lowering vehicle, and road testing.

Cleaning and Lubricant Usage Notes

Instructions for cleaning the jig and notes on BG HCF grease usage.

Service Bulletin Details and Warranty

Claim and Operation Information

Provides claim code, symptom code, and operation number for the repair.

Parts Information

Lists part numbers for damper grease and applicator jig, and kit discontinuation.

Warranty Information

Specifies application as normal warranty and causal part for VIN lookup.

This document outlines a service bulletin for Honda Civic 3 and 5 Door vehicles, addressing a common customer complaint regarding rear damper noise. The bulletin, numbered SJ-06-004-05 and issued on March 18, 2011, details a specific repair method for "Rear Damper Noise From Cold." The originator of this bulletin is David Peters from HUK (Honda UK).

Function Description:

The primary function of this service bulletin is to provide a comprehensive solution for a specific noise issue originating from the rear suspension dampers of certain Honda Civic models. The problem manifests as a "squeak and or knocking sound" from the rear suspension, particularly noticeable when the vehicle is first moved in the morning or after being parked overnight. This noise typically dissipates within five minutes of driving. The underlying cause is identified as a "stick slip friction action" between the piston rod and the main oil/wiper seals within the damper, leading to vibrations that produce the audible knock or squeak.

The countermeasure involves applying a specialized lubricant (grease) to the damper rod to reduce this friction. For production vehicles, the quantity of lubricating grease within the damper assembly has been increased. For aftersales service, a specific repair method is outlined, utilizing an application jig tool and a specified spray grease to lubricate the damper rod.

Important Technical Specifications:

The bulletin applies to the following Honda Civic models and their respective model codes and year models:

CIVIC 3D: FN1, FN2, FN3, FN4 (Year Models: 07, 08, 09, 10)
CIVIC 5D: FK1, FK2, FK3 (Year Models: 06, 07, 08, 09, 10)

The core of the repair involves the use of "BG HCF waterproof spray grease" and a "Grease Applicator Jig." The lubricant is applied in "short bursts" of approximately half a second each, equating to 1.75ml per burst. The repair is designed to be a permanent solution, and the BG HCF Grease is specifically chosen to prevent oil seal damage.

The bulletin also lists specific part numbers for the required materials:

Damper Grease: 52611-SMG-ZS00
Grease Applicator Jig: 52610-SMG-ZS00

Usage Features:

The repair method is designed for "On Customer Complaint Only," meaning it should only be performed when a customer reports the specific noise issue. The process involves several key steps:

Vehicle Preparation: Raise the vehicle on a lift, ensuring the wheels are free and off the ground. The rear dampers must be at full extension. Importantly, the rear wheels do not need to be removed for this repair.
Jig Priming: The applicator jig must be primed with the BG HCF grease. This involves shaking the grease can, attaching the tube between the aerosol can and the jig, spraying a priming shot of grease through the jig, and ensuring the grease exits freely.
Jig Insertion: Insert the grease applicator jig between the dust cover and the damper tube from the rear of the vehicle. It's crucial not to force the jig under the dust cover. A depth indication mark on the jig (labeled '2' in Fig B) must be aligned with the bottom of the dust cover (labeled '1' in Fig B) to ensure correct positioning.
Lubricant Application (First Pass): Connect the tube from the spray tin to the jig tool, ensuring it's fully inserted at both ends. Apply two short bursts of lubricant through the applicator jig. Each burst is a full depression and release of the nozzle.
Jig Rotation: Rotate the jig from the rear of the damper to face the front of the vehicle.
Lubricant Application (Second Pass): Reconnect the tube to the spray tin and the jig tool. Apply another two short bursts of lubricant through the applicator jig.
Repeat for Other Damper: This entire process must be repeated for the other untreated rear damper.
Post-Repair: After both sides are treated, lower the vehicle and road test it to confirm the noise has been eliminated.
Jig Maintenance: Clear the old grease from the applicator jig using an air gun and clean the tube, preparing it for the next vehicle.

Maintenance Features:

The bulletin emphasizes several critical maintenance and usage guidelines:

Lubricant Specificity: Only the "BG HCF waterproof spray grease" should be used for this repair. It is explicitly stated that this grease should not be used as a general workshop lubricant, nor should any other greases or lubricants be substituted, as they may negatively impact the repair's success.
Application Control: Technicians are warned not to over-spray the lubricant. Excessive application can create the appearance of a leaking damper on the outside of the damper tube, potentially leading to a misdiagnosis of leaking dampers later. If over-spray occurs, all visible grease must be cleaned off the damper tube.
Jig Longevity: If used correctly, one can of spray grease is sufficient to treat at least 55 vehicles.
Parts Availability: The initial free supply of the kit (grease and jig) has been discontinued. Additional grease or jigs must be ordered using the specified individual part numbers. These additional items are considered consumable and cannot be claimed under warranty.
Warranty Information: The repair falls under "Normal Warranty." The causal part for warranty claims is 52610-S**-*** (refer to Web EPC for the VIN being repaired). The claim code is 042, the NEWS Symptom Code is 04201 (Abnormal Noise), and the Operation No. (LON-NEWS Only) is 4170A2, with a Flat Rate Time (FRT) of 0.2 hours for treating both rear dampers with spray grease.