EVAP System - MIL ON/DTC P0440 or P0442 Set
BULLETIN NUMBER:SBO2-02-S001
ISSUE DATE:
APRIL 2002
GROUP:
FUEL SYSTEM
DTC P0440 (EVAP SYSTEM LEAK DETECTION) or P0442 (EVAP SYSTEM SMALL LEAK DETECTED) IS SET
AFFECTED VEHICLES
All 2001-2002 Rodeo (UE) prior to VIN breakpoint 924312426, and 2002 Axiom (UP) prior to VIN breakpoint 824610760.
SERVICE INFORMATION
Condition:
Customers may experience a check engine light condition generating diagnosis codes P0440 or P0442 code. Technician has diagnosed evaporative leak at fuel pump seal.
IMPORTANT:
Resetting the check engine light is not a warrantable repair if it is found to be set by customer not properly securing the gas cap. Any cost associated with resetting the check engine light is the responsibility of the customer as it is not a defect in material or manufacture of the vehicle.
Probable Cause
The 0-ring that seals the fuel pump to the tank is leaking.
Diagnosis:
1. Turn the ignition switch to the on position with the engine off.
2. Remove the fuel filler cap.
3. Using the TECH 2 Tester, check the Fuel Tank Pressure Sensor (FTSP) voltage.
^ If the voltage is between 1.42 volts and 1.58 volts, continue to the next step.
^ If the voltage is out of range, disregard this bulletin and check the connections in the FTPS circuit.
4. Reinstall the fuel filler cap at least three clicks.
5. Use a jumper wire and ground the brown/white wire at the canister vent solenoid.
6. Run the engine at 2500 RPM's until the FTPS voltage is 3.50. This will take a minute or less.
^ If the FTPS reaches 3.50 volts, continue to the next step.
^ If the FTPS voltage does not reach 3.50 volts, the EVAP system has an open hose, the purge solenoid is plugged or the canister vent solenoid is stuck open. Disregard this bulletin and troubleshoot for the above conditions. Start by pinching the vent solenoid hose closed and checking the FTPS again.
7. Disconnect the purge solenoid harness.
8. Idle the engine.
9. Monitor the FTPS voltage for 30 seconds.
^ If the voltage drops more than 0.10 volts, continue to Service Procedures.
^ If the voltage drops 0.10 volts or less, the fuel filler cap was not properly tightened at sometime in the past. Return the vehicle to the customer and advise them to tighten the cap three clicks or more in the future.
IMPORTANT:
Seals cannot be reused once removed from fuel tank assembly, before initializing service procedure confirm that mold 1 and mold 2 seals are available at your dealer location.
NOTE:
Protective eye wear should be worn during this procedure.
1. Park and secure the vehicle.
2. Record the radio mode settings and station presets.
3. Disconnect the battery ground cable.
4. Raise the vehicle on the hoist.
5. If vehicle is a Rodeo Sport use part number 8-97329-935-0. For Rodeo and Axiom. you must identify the fuel pump seal mold by placing a technician's inspection mirror between the fuel tank assembly and under- carriage. Select seal mold 1 for tank mold 1 and seal mold 2 for tank mold 2 (see service procedure # 16).
6. Loosen fuel filler cap to reduce the pressure in the tank.
7. Drain fuel from the fuel tank (refer to Work Shop Manual/ESI-CD).
8. Secure the fuel tank assembly by placing a support underneath the tank.
9. Disconnect the fuel feed hose and fuel return hose near the fuel filter.
NOTE:
Plug both ends to prevent fuel leakage.
10. Disconnect the fuel filler hose and fuel vent hose at the filler neck.
11. Disconnect the fuel breather hose and fuel evaporator hose.
NOTE:
Cover the fuel hoses to prevent any dust from the fuel tank.
12. Remove two (2) bolts to remove separator.
13. Remove the five (5) fuel tank assembly fixing bolts and one (1) nut.
14. Let down the tank and disconnect the wiring connectors.
IMPORTANT:
When removing tank use caution not to break or damage any of the plastic fittings.
15. Remove fuel tank assembly along with protector.
16. Remove fuel tube/quick connector.
17. Remove the fuel pump retainer with tool J-39765 and remove the fuel pump with sender (FPS) assembly.
IMPORTANT:
When removing retainer be sure to use only tool J-39765, using any other tool may damage the fuel tank assembly.
NOTE:
After removing fuel pump assembly, cover the fuel tank to prevent dust from entering.
18. Verify the fuel tank mold casting number (Mold 1 or Mold 2). Select the appropriate seal for the fuel tank mold of each vehicle (see part number list for selection) (Figure 1).
IMPORTANT:
Seal mold 1 must only be used on tank mold 1 and seal mold 2 (with blue markings) must only be used on tank mold 2. Correct seal selection is critical to vehicle repair.
19. Install the new seal onto the fuel tank (Figure 2 and 3).
20. Install the fuel pump assembly into the fuel tank. Confirm the pump is resting on the flat area in the bottom and is not tilted by interference with the positioning features on the bottom of the fuel tank assembly.
21. Verify the locating tab on the flange of the fuel pump assembly is located directly above the locating slot near the gasket groove of the tank assembly. Push down the top flange of the fuel pump to install retainer.
22. Install the fuel pump retainer with tool J-39765.
23. Install fuel tube/quick connector.
24. Raise the fuel tank and install the connectors.
25. Install fuel tank and tighten five bolts and one nut to specified torque (68 Nm) (50lb ft.)
26. Install the separator and tighten two bolts (10 Nm) (95lb in).
27. Connect fuel filler hose and fuel vent hose and clip them firmly.
28. Connect fuel feed hose and fuel return hose and clip them firmly.
29. Lower the vehicle from the hoist.
30. Tighten fuel filler cap with not less than 3 clicks.
31. Connect the battery ground cable.
32. Enter the radio mode settings and station presets, recorded earlier and reset the clock.
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
Use the labor operation table as shown.
WARRANTY CLAIM SUBMISSION INFORMATION
For your convenience, please use the information shown when submitting your warranty claim.