Recall - EVAP System Upgrades: Overview
03-040March 5, 2004
Applies To:
See VEHICLES AFFECTED
Product Update: EVAP Canister Drain Joint
(Supersedes 03-040, dated July 31, 2003)
Updated information is shown with asterisks.
BACKGROUND
In wet conditions, moisture can enter the EVAP canister at its drain joint. This can cause the MIL to come on with DTC P0497 (EVAP system low purge flow) or DTC P2422 (EVAP system vent shut valve close malfunction).
VEHICLES AFFECTED
Not all vehicles within the VIN ranges are affected by this product update. 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 on your campaign responsibility report.
^ The vehicle is shown as eligible on an iN VIN status inquiry.
* In addition to the bulleted verification items, check for a punch mark above the third character of the engine compartment VIN. A punch mark in that location means this campaign has already been done.*
CUSTOMER NOTIFICATION
All owners of affected vehicles will be sent a notification of this product update. The customer notification may also contain information on other product updates. An example of the customer notification for the EVAP canister product update is shown in this service bulletin.
CORRECTIVE ACTION
If the MIL is off, replace the EVAP canister drain joint, and install a foam gasket around it.
If the MIL is on, retrieve the DTC(s), then replace the EVAP canister, the EVAP canister vent shut valve, and the EVAP canister drain joint, and install a foam gasket around the drain joint.
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
Failed Part: P/N 17742-SDA-A02
H/C 7522659
Defect Code: 5CD
*Symptom Code: P00*
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
If the MIL is off, do Repair Procedure A. If the MIL is on, do Repair Procedure B.
Repair Procedure A - MIL Is Off
1. Remove the left rear wheel.
2. Disconnect the ABS wheel sensor connector, then remove the bolt from the sensor harness, and move the harness out of the way.
3. Pull the EVAP hose off the drain joint, then remove and discard the drain joint.
4. Remove any Hondabond material from the drain joint area on the subframe.
5. Install the foam gasket and the new drain joint on the subframe.
6. Attach the EVAP hose to the drain joint.
7. Install the ABS sensor harness, and torque the bolt to 9.8 Nm (7.2 lb-ft). Connect the wheel sensor connector.
8. Install the wheel, and torque the lug nuts to 108 Nm (80 lb-ft).
9. Center-punch a completion mark above the third character of the engine compartment VIN.
10. * For California residents: Fill out and give to your customer a Vehicle Emission Recall - Proof of Correction certificate. On the certificate, write down P00 as the recall number. Advise your customer to keep this certificate as proof that the product update was completed. They will need to submit this certificate to the DMV if the DMV requests it. A supply of these salmon-colored certificates was sent to your service manager. If you need more, use reorder number Y0657.*
Repair Procedure B - MIL Is On
1. Retrieve the DTC(s) with the HDS (Honda Diagnostic System).
^ If DTC P0497 or P2422 is stored, clear the DTC, then go to step 2.
^ If other DTCs are stored, troubleshoot them using the 2003 Accord Service Manual, then go to step 2.
2. Remove the left rear wheel.
3. Disconnect the ABS wheel sensor connector, then remove the bolt from the sensor harness, and move the harness out of the way.
4. Pull the EVAP hose off the drain joint, then remove and discard the drain joint.
5. Disconnect the EVAP canister lines from the canister, then blow compressed air through the lines to clear them of any water or ice.
6. Remove any Hondabond material from the drain joint area on the subframe.
7. Install the foam gasket and new drain joint on the subframe.
8. Attach the EVAP hose to the drain joint.
9. Replace the EVAP canister (see page 11-289 of the service manual). Use the parts catalog to select and order the correct part.
10. Replace the EVAP canister vent shut valve (see page 11-291 of the service manual). Use the parts catalog to select and order the correct part.
NOTE:
If you're working on a SULEV model, you also need to replace the EVAP canister filter. Use the parts catalog to select and order the correct part.
11. Install the ABS sensor harness, and torque the bolt to 9.8 Nm (7.2 lb-ft). Connect the wheel sensor connector.
12. Install the wheel, and torque the lug nuts to 108 Nm (80 lb-ft).
13. Center-punch a completion mark above the third character of the engine compartment VIN.
14. * For California residents: Fill out and give to your customer a Vehicle Emission Recall - Proof of Correction certificate. On the certificate, write down P00 as the recall number. Advise your customer to keep this certificate as proof that the product update was completed. They will need to submit this certificate to the DMV if the DMV requests it. A supply of these salmon-colored certificates was sent to your service manager. If you need more, use reorder number Y0657.*
Disclaimer