Interior - Sulfur/Rotten Egg Smell in the Interior
03-031July 13, 2004
Applies To:
2002-04 RSX (Except Type S) - ALL
Sulfur Smell in the Interior
(Supersedes 03-031, dated November 14, 2003)
Updated information is shown by asterisks and a black bar.
SYMPTOM
Sulfur or rotten egg smell in the interior.
PROBABLE CAUSE
Unsealed body seams are allowing a sulfur smell to enter the interior.
CORRECTIVE ACTION
On all 2002-03 models, seal the open body seams, install flaps on the tailgate drain holes, and replace the catalytic converter. On the 2004 model, only replace the catalytic converter.
PARTS INFORMATION
Catalytic Converter: P/N 18160-PND-305
Pre-Chamber Gasket: P/N 18393-SH3-S00
Exhaust Flexible Gasket: P/N 18229-S6M-003
Flexible Joint Bolt (2 required): P/N 18231-SR3-A22
Self-Locking nuts (3 required): P/N 90212-5A5-003
Flap Seal: P/N 90856-56M-305
(One strip repairs four vehicles.)
Air Door Outlet: P/N 75450-56M-000
Grommet: P/N 91611-SS0-003
REQUIRED MATERIALS
3M Ribbon Sealer: 3M P/N 08612
(One roll repairs three vehicles.)
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Failed Part: P/N 18160-PND-A00
Defect Code: 07408
Symptom Code: 06006
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
NOTE:
For 2004 models, go to step 12.
1. Remove the rear bumper face, absorber, and beam (see page 20-89 of the 2002-04 RSX Service Manual).
2. Wash the area of the body panels that were covered by the bumper face, absorber, and beam.
3. Remove the left, right, and rear cargo area linings.
4. Check for gaps around the left and right side air outlets, and make sure that the air door fits snugly into the frame. If you find gaps or the air door does not fit snugly, replace the air door.
5. Check the grommets on the left and right sides on the back panel. If you find a missing grommet(s), install a new grommet(s).
6. Inspect the dust seal on the seam where the side panel meets the floor panel in the area just below the air outlet. If you find any cracks, seal them with ribbon sealer.
7. Degrease the left and right ends of the bumper beam frame.
8. Fill the holes shown with ribbon sealer, and apply ribbon sealer around the seam on the frame ends. Do not seal the drain hole on the bottom at each bumper beam frame; leave it open.
9. In the cargo area, remove the damper gussets, and degrease the areas around the left and right dampers. Apply ribbon sealer on the left and right seams where the floor panel meets the damper base. Reinstall the damper gussets, and torque the nuts to 59 N.m (43 ft-lb).
10. Inspect the factory dust sealer on both sides of the cargo area panel. There should be no visible gaps or cracks. If you find any gaps or cracks, apply ribbon sealer to the area.
*11. Cut four 20-mm-long pieces of the flap seal self-adhesive strip. Clean the area, and apply these pieces to the four drain holes. Make sure the sticky side of the adhesive is on the top part of the trunk lid and the non-sticky side is over the drain hole towards the trunk lid edge.
NOTE:
Do not cover the drain hole with the sticky portion of the flap seal.*
12. Remove the air fuel ratio sensor and the secondary heated oxygen sensor from the catalytic converter.
13. Remove the catalytic converter, and install the new catalytic converter.
14. Using new exhaust gaskets, nuts, and bolts, torque the self-locking nuts to 33 N.m (25 lb-ft) and torque the bolts to 22 N.m (16 lb-ft). Torque the upper bolts in steps, alternating from side to side.
15. Reinstall the air fuel ratio sensor and the secondary heated oxygen sensor. Torque both to 44 N.m (33 lb-ft).
16. Reinstall the cargo area lining, the rear panel, and the rear bumper beam, absorber, and face.
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