NHTSA Complaint #11584638 — 2012 HONDA ODYSSEY

The front valve cover is exposed to extreme temperatures from the catalytic converter mounted next to it. There is nothing to protect the rubber components inside from the catalytic converter's excessive heat which is causing them to fail. The steel components inside the cylinder (e.g., the seal ring) are insulated by these rubber components. When these rubber insulators fail, the steel components are exposed and make contact with the aluminum valve cover resulting in the galvanic corrosion of the aluminum. The most common result I have seen is the deformation of the area where the seal ring is seated (along with holes and cracks). Some people have also suggested possible defects in the casting of the aluminum as a contributing factor (the aluminum is also very thin in that area). Some have suggested the possibility of the uninsulated spark plug arcing, but it seems unlikely to generate enough heat to compromise the aluminum's integrity. The way people have described how the aluminum crumbles seems more indicative of corrosion. There are countless testimonies online of similar defects in Odysseys, Pilots, Accords, and Crosstours with the same engine. I have included a photograph of my damaged valve cover and those of others I have found online.