Campaign - EGR Valve Warranty Extension: Overview
05-019February 5, 2008
Applies To:
2001 - 02 MDX - ALL
Warranty Extension: EGR Valve Contamination May Cause Engine
Hesitation/Surge or DTC P1491
(Supersedes 05-019, dated July 20, 2005, to update the information marked by asterisks)
BACKGROUND
*NOTE:
Because of a class action settlement, the warranty extension coverage for the EGR valve on 2002 MDXs purchased or leased between April 13, 2002, and November 7, 2006, is 8 years or 84,000 miles, whichever occurs first. For more information, refer to Service Bulletin 06-050, Warranty Extension: Vehicle Warranty Mileage.*
In some 2001-02 MDXs, the EGR valve can become contaminated. If this happens, the vehicle may hesitate or surge during light acceleration, and the MIL (malfunction indicator lamp) may come on with DTC P1491 (EGR valve insufficient lift).
Because of this possible problem, the EGR valve warranty is being extended to 8 years or 80,000 miles, whichever occurs first. For a vehicle to be eligible, the EGR valve malfunction must be confirmed with the inspection procedure in this bulletin.
CUSTOMER NOTIFICATION
Owners of affected vehicles were mailed a letter about the EGR 8/80 warranty extension. An example of the letter is at the end of this service bulletin.
CORRECTIVE ACTION
Test-drive the vehicle with the HDS connected to check the EGR valve. If needed, replace the valve, and clear any stored DTCs.
PARTS INFORMATION
EGR Valve Set: P/N 18011-PGK-A02
(Contains EGR valve and EGR valve gasket)
WARRANTY CLAIM INFORMATION
Failed Part: P/N 18011-PGK-A02
Defect Code: 5KE00
Symptom Code: P7600
Skill Level: Repair Technician
INSPECTION PROCEDURE
1. Verify that the HDS has software version 1.017.006 or later installed. Previous versions may not work.
2. Connect the HDS to the vehicle's 16P data link connector (DLG).
3. Turn the ignition switch to ON (II), and turn on the HDS.
4. At the screen prompts, enter the VIN and the odometer reading, then verify the correct date/time.
5. Select the Mode Menu. Then select Honda Systems.
6. From the System Selection Menu screen, select PGM F1.
7. From the Mode Menu screen, select Snapshot.
8. From the Trigger Type menu, select the High Speed Set-up button.
9. From the High Speed menu screen, select these parameters: Engine Speed, VSS, ECT Sensor, Map Sensor, TP Sensor, EGR-L-Command, and EGR LIFT. Then select the green Check button.
10. When the Trigger Type menu is displayed, select Manual, select Record Time for 30 seconds, and move the trigger point to the middle. Then select the Blue Check button. Make sure the defaulted trigger point is in the middle.
11. With the engine completely warmed up, have an assistant drive the vehicle while you operate the HDS. Drive the vehicle between 40 and 55 mph on a smooth road. Apply light throttle with the transmission in 5th gear (between 1,500 and 2,000 rpm). If hesitation is felt, select the Snapshot Manual Trigger button.
NOTE:
The snapshot must be done with two people so that one person can drive and the other can operate the HDS.
12. When the drive is complete, the Snapshot dialog box is displayed. Select Yes, then select OK. This stores the snapshot.
13. Select the Folder button, then select the Snapshot you just created.
14. Select the Tool button. Under the line graph column, select EGR L COMMAND and EGR LIFT.
15. Select the Line Graph button.
^ If the EGR LIFT graph is different from the EGR L COMMAND graph, the EGR valve is bad. Go to REPAIR PROCEDURE.
^ If the EGR LIFT graph follows the EGR L COMMAND graph, the EGR valve is OK. Continue with normal troubleshooting procedures.
REPAIR PROCEDURE
1. Remove the intake manifold cover.
2. Remove the EGR valve.
3. Install the new gasket and the EGR valve. Torque the nuts to 22 N~m (16 lb-ft). Reconnect the EGR valve connector, and install the intake manifold cover.
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