Fuel/Emissions - MIL ON/DTC P0401 Set

08-006

March 26, 2008

Applies To:
2005-07 RL - ALL

2008 RL - From VIN JH4KB16..8C000001 thru JH4KB16..8C004681

MIL Comes On With DTC P0401

(Supersedes 08-006, dated March 14, 2008, to update the information marked by the black bar)

SYMPTOM

The MIL comes on with DTC P0401 (EGR insufficient flow).

PROBABLE CAUSE

The fuel injectors' spray pattern creates unwanted carbon buildup around the EGR valve opening, which restricts the airflow.

CORRECTIVE ACTION

Replace the fuel injectors and the EGR valve.

PARTS INFORMATION

EGR Valve:
P/N 18011-PXK-030

Fuel Injectors (Qty. 6):
P/N 16450-R70-A01

Intake Manifold Gasket:
P/N 17105-RCA-A01

Upper Intake Manifold Cover Gasket:
P/N 17146-RKB-003

WARRANTY CLAIM INFORMATION

In warranty:
The normal warranty applies.

NOTE:
Separate claims must be filled out for the EGR valve replacement and the fuel injector replacement.

Failed Part: EGR valve:
P/N 18011-PXK-030

Fuel injectors:
P/N 16450-R70-A01

Defect Code: EGR replacement: 03214
Fuel injector replacement: 03217

Symptom Code: EGR replacement: 03203
Fuel injector replacement: 03205

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

1. Replace the EGR valve:

^ Refer to page 11-379 in the 05-08 RL Service Manual, or

^ Online, enter keywords EGR REPLACE, and select EGR Valve Replacement from the list.

2. Replace all of the fuel injectors:

^ Refer to page 11-214 in the service manual, or

^ Online, enter keyword INJECTOR, and select Injector Replacement from the list.

3. Clear the DTC with the HDS.





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