Attachment II - Repair Procedures
A. VEHICLE INSPECTION PROCEDURE1. Verify that the vehicle is within the following range:
^ 2002 - 2003 MPV vehicles built from November 26, 2001 through August 8, 2003 VIN Range: JM3LW28**2*300020 - JM3LW28**3*378984
- If the vehicle is within the above range, proceed to Step 2.
- If the vehicle is not within the above range, return the vehicle to the customer or inventory.
2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for an Authorized Modification Label Recall 2204H attached to the vehicle's hood. Refer to eMDCS System - Warranty Vehicle Inquiry Results table.
NOTE:
Be sure to verify RECALL number as the vehicle may have multiple Recall labels.
B. REPAIR PROCEDURE
WARNING:
Allow the engine to sufficiently cool down before performing this repair.
PCV HOSE REMOVAL:
1. Record customer's pre-set radio stations.
2. Remove the Battery, Air Cleaner Case, and Intake Air Hose to gain access to the PCV hose.
3. Locate the PCV hose on the back of the intake manifold.
4. Pull the end of the PCV hose from the plastic joint connector.
5. Obtain a hose clamp removal tool (i.e. Snap-on - Hose Clamp Pliers, # YA28650) or other suitable tool.
6. Using the tool, squeeze and release the large hose clamp at the back of the intake manifold.
7. Remove the PCV hose from intake manifold.
8. Remove and discard the tie-wrap.
9. Remove the PCV hose from the vehicle and proceed to "C. INSPECTION PROCEDURE" to identify the type of PCV hose found on the vehicle.
C. INSPECTION PROCEDURE
PCV HOSE INSPECTION:
1. Identify the type of PCV hose installed on the vehicle by comparing the shape of the PCV hoses.
NOTE:
The new style hose is approx. 20" in length, is not pre-formed, and has a larger outer diameter than the old style hose.
2. Inspect the hose for damage (heat marks, cut, split, etc.).
3. After identifying the type and condition of the PCV hose, use the "PCV Hose Inspection Results" table shown to determine the required action.
CAUTION:
IF A NEW STYLE HOSE IS FOUND ON THE VEHICLE. IT MUST BE REPLACED IF IT IS DAMAGED.
D. REPAIR PROCEDURE PCV HOSE INSTALLATION:
NOTE:
DO NOT remove the "retaining clip" from the new PCV hose clamp at this time. If the new style hose was already installed on the vehicle, the retaining clip will not be present.
1. Attach the large hose end to the intake manifold.
2. Twist the large hose end counter-clockwise so the hose clamp faces the driver side of the vehicle, and the hose is routed away from the EGR pipe.
NOTE:
It is very important to twist the hose to provide the necessary clearance between the PCV hose and the EGR Pipe.
3. Attach the other end of the new PCV hose to the plastic joint connector.
NOTE:
Ensure the hose is fully seated onto the connector. Confirm the connector hose is fully seated onto the PCV valve.
4. Pull off the "retaining clip" from the hose clamp to secure the new PCV hose; discard the retaining clip.
5. Install a tie-wrap (not supplied) around the new hose as shown.
CAUTION:
A TIE-WRAP MUST BE INSTALLED TO KEEP THE NEW PCV HOSE IN PROPER POSITION AND AWAY FROM THE EGR PIPE. CONFIRM THERE IS A MINIMUM OF 1/2" CLEARANCE BETWEEN THE PCV HOSE AND THE EGR PIPE. IF THE PCV HOSE CONTACTS THE EGR PIPE. THE PCV HOSE MAY BE DAMAGED.
6. Reinstall the Intake Air Hose, Air Cleaner Case, and Battery.
7. Start the engine and confirm no vacuum leaks are present.
8. Re-enter the customer's pre-set radio stations.
9. Proceed to "E. AUTHORIZED MODIFICATION LABEL INSTALLATION."
E. AUTHORIZED MODIFICATION LABEL INSTALLATION
Complete an "Authorized Modification Label" with the Recall number written on the sticker and affix it to the vehicle's hood. Refer back to the illustration under "A. VEHICLE INSPECTION PROCEDURE".