NHTSA Complaint #11455723 — 2011 HONDA PILOT

The front cylinder head valve cover developed an erosion hole adjacent to the middle spark plug (#5) tube cutout. The valve cover is available for inspection. This portion of the valve cover is directly above the oxygen sensor on the exhaust manifold. Engine oil could leak onto the hot manifold and ignite, causing an engine fire. I have not taken this cover to a Honda dealer or independent service center as I do my own maintenance work on my vehicles. This failure occurred after 153,235 miles and there were no indications, messages, or symptoms. The hole was not leaking oil as it was filled with valve cover material that had degraded and turned into powder. The powder was easily dislodged after probing with a metal pick, leaving a hole in its place. The #5 ignition coil was inspected and was visually unremarkable. The engine was not misfiring. The MIL lamp was off and there were no DTC codes present. A web search found several other complaints about this issue (with pictures of incidents of greater severity) and it is not confined to Honda vehicles.