Fuel/Emissions - MIL ON/DTC P01456 (EVAP System)
04-002February 13, 2004
Applies To:
See VEHICLES AFFECTED
Fuel Fill Cap Binds and Possible MIL Comes On With DTC P1456
(Supersedes 04-002, dated January 30, 2004)
Updated information is shown with black bars.
SYMPTOM
The fuel fill cap is binding and, if not tightened fully, may cause the MIL to come on and DTC P1456 (EVAP control system leakage, fuel tank system) to set.
PROBABLE CAUSE
The threads in the fuel fill pipe bind on the fuel fill cap.
VEHICLES AFFECTED
CORRECTIVE ACTION
Replace the fuel fill pipe, and do an EVAP system function test with the HDS.
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
In warranty: The normal warranty applies.
Failed Part: P/N 17660-S9A-A01
H/C 6887210
Defect Code: 03214
Symptom Code: 03203
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
Remove the fuel fill cap, reinsert it, then tighten it. The cap should turn, without resistance, until its 0-ring touches the fuel fill pipe.
^ If the cap turns freely, this service bulletin does not apply; continue with normal troubleshooting.
^ If the cap binds or drags, go to REPAIR PROCEDURE.
REPAIR PROCEDURE A - CR-V
NOTE:
Make sure the fuel tank is less than half full before starting this procedure.
1. Raise the vehicle on a lift, and remove the left rear wheel.
2. Remove the three EVAP canister mounting bolts. Let the canister hang in place.
3. Support the rear suspension cross beam with a powertrain lift or commercially available jack as shown.
4. Disconnect the fuel fill pipe hoses from the fuel fill pipe.
5. Remove the two lower rear cross beam bolts, the two fuel fill pipe bracket bolts, and the fuel fill pipe gasket.
6. Using a pry bar, move the rear cross beam down to make room to remove the fuel fill pipe.
7. Install the new fuel fill pipe, the fuel fill pipe gasket, and the hoses. Torque the two cross beam bolts to 69 Nm (51 lb-ft). Reinstall the EVAP canister and the wheel.
8. Connect the HDS to the vehicle's DLC (data link connector), and do the EVAP function test:
^ From the HDS main menu, select Honda System.
^ From the Honda System menu, select PGM-FI.
^ From the PGM-FI menu, select Inspection.
^ From the Inspection menu, select EVAP Test.
^ From the EVAP Test menu, select Function Test.
^ Follow the instructions on the screen.
9. Check the results of the EVAP function test.
^ If the vehicle passed the test, return it to the customer.
^ If the vehicle failed the test, do the DTC P1456 troubleshooting in section 11 of the appropriate CR-V service manual.
REPAIR PROCEDURE B - S2000
NOTE:
Make sure the fuel tank is less than half full before starting this procedure.
1. Remove the left side trunk lining.
2. Slide up the fuel fill pipe cover, and disconnect the fuel fill pipe hoses.
3. Remove the fuel fill pipe attachment nuts.
4. Install the new fuel fill pipe with the original nuts.
5. Install the fuel fill pipe hoses with the original clamps. Make sure the fuel fill pipe cover is seated properly. Install the trunk lining.
6. Connect the HDS to the vehicle's DLC (data link connector), and do an EVAP function test:
^ From the HDS main menu, select Honda System.
^ From the Honda System menu, select PGM-FI.
^ From the PGM-FI menu, select Inspection.
^ From the Inspection menu, select EVAP Test.
^ From the EVAP Test menu, select Function Test.
7. Check the results of the EVAP function test.
^ If the vehicle passed the test, return it to the customer.
^ If the vehicle failed the test, do the DTC P1456 troubleshooting in section 11 of the 2002-04 S2000 Service Manual.
REPAIR PROCEDURE C - INSIGHT
1. Remove the trunk lining and the cargo box. (See page 20-44 of the 2000-04 Insight Service Manual.)
2. Remove the right trunk side bulkhead and the right side trunk shelf support.
3. Remove the middle floor pan. (See page 20-92 of the 2000-04 Insight Service Manual.)
4. Remove the battery inner duct and the fuel fill pipe grommet.
5. Slide the fuel fill pipe grommet upward. Then disconnect the fuel fill pipe hoses.
6. Remove the fuel fill pipe bracket bolt and the three fuel fill pipe flange nuts.
7. Install the new fuel fill pipe with the original nuts and bolt.
8. Install the fuel fill pipe hoses with the original clamps. Install the fuel fill pipe grommet.
9. Reinstall all removed parts.
10. Connect the HDS to the vehicle's DLC (data link connector), and do the EVAP function test:
^ From the HDS main menu, select Honda System.
^ From the Honda System menu, select PGM-FI.
^ From the PGM-FI menu, select Inspection.
^ From the Inspection menu, select EVAP Test.
^ From the EVAP Test menu, select Function Test.
^ Follow the instructions on the screen.
11. Check the results of the EVAP function test.
^ If the vehicle passed the test, return it to the customer.
^ If the vehicle failed the test, do the DTC P1456 troubleshooting in section 11 of the 2000-04 Insight Service Manual.
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