Recall - EGR System Warranty Extension
99-045December 17, 2001
Applies To:
1997-99 3.0CL - ALL
3.0CL Warranty Extension: EGR Port Clogging
(Supersedes 99-045, dated October 26, 2001)
Updated information is shown by black bars.
BACKGROUND
In some areas of the U.S., certain basic chemical properties of gasoline (regardless of brand) may cause the intake manifold EGR port to clog or the EGR valve to fail. If this happens, the MIL comes on with a DTC P0401 (insufficient EGR flow) or P1491 (insufficient EGR lift) stored.
WARRANTY EXTENSION INFORMATION
This warranty extension cancels the PCV hose routing Product Update Campaign. You should no longer install the PCV hose routing kit.
1997 vehicles - These vehicles are covered by the 14 year, 150,000 mile emissions warranty extension. Refer to service bulletin 98-031, Emissions Warranty Extension, filed under Fuel and Emissions. Any condition that causes the MIL to come on is covered by this warranty extension.
1998-99 vehicles - American Honda is extending the warranty on EGR system problems in the affected vehicles to 8 years or 80,000 miles, whichever comes first. To be eligible for coverage under this extended warranty, the MIL must be on with one of the above DTCs stored. Install the EGR pipe kit, and file a claim using the information in this service bulletin.
CUSTOMER NOTIFICATION
1997 vehicles - All 1997 vehicles were subject to the PUD. Owners will be mailed a letter explaining that the PUD has been cancelled, and reminding them that the emissions systems are covered by the 14 year, 150,000 mile emissions warranty extension.
1998-99 vehicles - The PUD covered all of the 1998 model year, and the first part of the 1999 model year. Owners of these vehicles will be mailed a letter explaining that the PUD has been cancelled, and detailing the 8 year, 80,000 mile warranty extension covering EGR system clogging.
1999 vehicles - The remainder of the 1999 model year is being added to the warranty extension. Owners of these vehicles will be mailed a letter detailing the 8 year, 80,000 mile warranty extension covering EGR system clogging.
Examples of the customer notifications are shown.
CORRECTIVE ACTION
Clean the EGR port, and install the EGR pipe kit.
PARTS INFORMATION
TOOL INFORMATION
WARRANTY CLAIM INFORMATION
REPAIR PROCEDURE
1. Remove the throttle body cover, intake manifold covers, ignition wire holder, and ignition wire cover.
2. Disconnect the brake booster vacuum hose and the vacuum hose from the intake manifold.
3. Remove the throttle body from the intake manifold (two nuts and two bolts). Leave all hoses, cables, and electrical connectors connected to the throttle body. Discard the throttle body gasket(s).
4. Remove the PCV valve from the cylinder head cover. Remove the intake manifold (three nuts and six bolts).
5. Remove the intake manifold chamber, IAT sensor, boost plate, and PCV hose from the intake manifold.
6. Cover the six ports on the bottom of the manifold with duct tape.
7. Use an 8 mm drill bit and carburetor cleaner to clean the EGR port in the intake manifold. Turn the drill bit only by hand. Do not use a power drill.
8. Put the special drill bit from the EGR pipe installation kit in your power drill. Coat the drill bit completely with clean engine oil.
NOTE:
The oil coating is critical to drilling the hole accurately, and it contributes to drill bit life.
9. Insert the guide part of the drill bit into the EGR port. Make sure it is inserted fully. Then drill out the EGR port using steady pressure on the drill. Make sure the port is drilled through completely.
10. Clean up the aluminum chips from drilling, then remove the duct tape.
11. Put the manifold in a parts washer (solvent or soap and water) and clean it thoroughly.
^ Flush out the EGR port for 20 seconds (1).
^ Flush out the manifold from the throttle body opening. Run cleaner down each side for 20 seconds (2).
^ Flush each intake runner for 10 seconds (3). Start at the throttle body end and work toward the back.
^ Turn the manifold so the throttle body opening is facing down. Flush each main runner for 20 seconds (4).
^ Dry the manifold with compressed air and clean shop towels.
12. Place the EGR pipe from the kit into the EGR port.
13. Use the installation tool and a small hammer to drive the EGR pipe into the port until it is flush with the port. Make sure the pipe will not contact the gasket after installation.
14. Install the intake manifold chamber; torque the nuts and bolts to 12 N.m (8.7 lb-ft). Install the IAT sensor; torque it to 18 N.m (13 lb-ft). Install the boost plate; torque the bolts to 12 N.m (8.7 lb-ft). Install the PCV hose.
15. Inspect the EGR port in the front of the injector base on the engine. If it is partially or fully clogged, clean the port.
16. Disconnect the 6P connector from the EGR valve. Remove the EGR valve.
17. Install the new EGR valve with a new gasket. Torque the mounting nuts to 22 N.m (16 lb-ft). Reconnect the 6P connector.
18. Install the intake manifold with the original gasket. Torque the mounting nuts and bolts to 22 N.m (16 lb-ft) sequentially in two or three steps. Route the PCV hose so it is not pinched under the intake manifold.
19. Install the PCV valve in the cylinder head cover.
20. Install the throttle body with a new gasket(s). Torque the mounting nuts and bolts to 22 N.m (16 lb-ft).
21. Reinstall the brake booster vacuum hose, vacuum hose, ignition wire holder, and all of the covers.
22. Connect the PGM Tester (loaded with SN2OO or later software). Clear any DTCs.
23. Jump the Service Check Connector (located behind the glove box) with the SCS Service Connector (T/N 07PAZ-0010100). This disables two-trip error detection. Test-drive the vehicle to make sure the MIL does not come back on.
24. Remove the SCS Service Connector, and return the vehicle to the customer.
DISCLAIMER