Canada - Fuel - MIL ON/DTC P0440/P0441/P0442/P0446/P0456

Bulletin
TSB2496R

Issue Date
2007-01-15

Market
Canada

Title
M.I.L. "ON" DTC P0440, P0441, P0442, P0446, OR P0456 - FUEL FILLER TUBE IMPROVEMENT

Component
ENGINE MECHANICAL

Models
'03 - '04 Corolla & Matrix 2WD, & '05 Matrix 4WD

INTRODUCTION:
Some 2003 -- 2004 model year Corolla and Matrix 2WD and 2005 model year Matrix 4WD vehicles may exhibit a M.I.L. "ON" condition with DTCs P0440, P0441, P0442, P0446, or P0456 stored. An improved fuel filler tube has been developed to correct this condition.

APPLICABLE VEHICLES:
- 2003 - 2004 model year Corolla and Matrix vehicles equipped with 2WD.
- 2005 model year Matrix vehicles equipped with 4WD.






PARTS INFORMATION:






WARRANTY INFORMATION:






REQUIRED SSTs:

REPAIR PROCEDURE:
1. Using the Diagnostic Tester, check for diagnostic trouble codes (DTCs). If P0440, P0441, P0442, P0446, and/or P0456 are present, inspect the fuel cap sealing surface on the Fuel Tank Filler Pipe Sub-assembly for corrosion.
- If corrosion is present, proceed to step 2.
- If no corrosion is present, proceed to step 5.

2. Replace the Fuel Tank Filler Pipe Sub--assembly with the updated part
3. Inspect the fuel cap o--ring for damage. If damage is present, replace the fuel cap.
4. Run the EVAP Monitor to confirm the repair.
Refer to ETAS:
- 2004 model year Corolla Repair Manual: Diagnostics: SFI System (April 2003): Readiness Monitor Drive Pattern
- 2004 model year Matrix Repair Manual: Diagnostics: SFI System (1ZZ--FE) or (2ZZ--FE) (May 2003): Readiness Monitor Drive Pattern
- 2005 model year Matrix Repair Manual: Diagnostics: SFI System (1ZZ--FE(4WD)): Readiness Monitor Drive Pattern

5. If another EVAP system fault is present, refer to ETAS and diagnose the fault accordingly:
- 2003 or 2004 model year Corolla Repair Manual:
- Emission Control: Emission Control System: On--Vehicle Inspection
- Emission Control: Emission Control System: Inspection

- 2003 or 2004 model year Matrix Repair Manual: Emission Control: Emission Control System: (1ZZ--FE) or (2ZZ--GE) On--Vehicle Inspection
- 2005 model year Matrix Repair Manual: Diagnostics: SFI System (1ZZ--FE(4WD)): P0442, P0456 Evaporative Emission Control System Leak Detected