Campaign - EGR System Contamination/Clogging: Overview
05-026February 5, 2008
Applies To:
1999-02 Odyssey - ALL
2003 Odyssey
From VIN 2HKRL18..3H500001 thru 2HKRL18..3H504511
and from VIN 5FNRL18..3B000001 thru 5FNRL18..3B067057
2003 Pilot
From VIN 2HKYF18..3H500001 thru 2HKYF18..3H567864
Warranty Extension: EGR Valve Contamination or EGR Port Clogging May Cause DTC P0401, DTC P1491, or Engine Hesitation/Surge
(Supersedes 05-026, dated July 20, 2005)
Updated information is shown with asterisks.
BACKGROUND
*NOTE:
Because of a class action settlement, the warranty extension coverage for EGR valve sticking on 2002-03 Odysseys and 2003 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 8 years or 84,000 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.*
In some 1999-03 Odysseys and 2003 Pilots, the EGR system may become contaminated or clogged. If this happens, the vehicle may hesitate or surge during light acceleration, and the MIL (malfunction indicator lamp) may come on with DTC P0401 (EGR insufficient flow) or P1491 (EGR valve insufficient lift).
Because of these possible problems, affected vehicles now have a warranty extension that covers EGR port clogging and/or EGR valve sticking.
Here are the details of the extended coverage:
^ On 1999-01 Odysseys thru VIN 2HKRL18..1H586575, EGR port clogging and EGR valve sticking is covered for 8 years or 80,000 miles, whichever occurs first.
^ On 2001 Odysseys after VIN 2HKRL18..1H586575, all 2002 Odysseys, 2003 Odysseys within the affected VIN ranges, and 2003 Pilots within the affected VIN range, EGR valve sticking is covered for 8 years or 80,000 miles, whichever occurs first.
For a vehicle to be eligible, the EGR valve malfunction must be confirmed with the hesitation/surge diagnosis in this bulletin, or the MIL must be on with DTC P0401 or P1491 stored.
VEHICLES PREVIOUSLY REPAIRED
To see if a vehicle was previously repaired according to S/B 00-009, do a VIN status inquiry. The warranty symptom code for vehicles repaired by S/B 00-009 is L38.
CUSTOMER NOTIFICATION
Depending on the vehicle and its problem, customers were sent one of these two letters:
Letter 1 is being sent to owners of 1999-00 Odysseys and 2001 Odysseys thru VIN 2HKHL18..1H586575.
These vehicles were not yet repaired according to S/B 00-009. This letter explains the 8/80 warranty extension. It also tells how EGR system contamination or clogging can cause engine hesitation or surging and cause the MIL to come on. The repair for these vehicles is to install an EGR pipe kit.
Letter 2 is being sent to owners of 1999-2001 Odysseys that were already repaired according to S/B 00-009, and all other vehicles with the affected VIN ranges. This letter explains the 8/80 warranty extension. It also tells how EGR valve contamination can cause engine hesitation or surging.The repair for these vehicles is to replace the EGR valve.
Examples of both letters are shown in this service bulletin.
CORRECTIVE ACTION
On 1999-01 Odysseys thru VIN 2HKRL18..1H586575 not yet repaired according to S/B 00-009:
If DTC P0401 or P1491 is stored, or if the engine hesitate or surges, clean the EGR port, install an EGR pipe kit, and clear the DTC(s) with the HDS (see REPAIR PROCEDURE B: EGR PORT CLEANING AND INSTALLATION OF EGR PIPE KIT)
On 1999-01 Odysseys thru VIN 2HKRL18..1H586575 already repaired according to S/B 00-009, and all other vehicles within the affected VIN ranges:
Test-drive the vehicle with the HDS to check the EGR valve. If needed, replace the valve, and clear any stored DTCs (see DIAGNOSIS OF HESITATION/SURGE).
PARTS INFORMATION
TOOL INFORMATION
WARRANTY CLAIM INFORMATION
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.
DIAGNOSIS OF HESITATION/SURGE
NOTE:
If you are working on a 1999-01 Odyssey thru VIN 2HKRL18..1H586575 not yet repaired according to S/B 00-009, do not do this diagnosis; go to REPAIR PROCEDURE B: EGR PORT CLEANING AND INSTALLATION OF EGR PIPE KIT.
1. Verify that the HDS has software version 1.017.006 or later installed. Previous versions will not do this diagnosis.
2. Connect the HDS to the vehicle's 16P data link connector (DLC).
3. Turn the ignition switch to ON (II). Turn on the HDS.
4. At the screen prompts, enter the VIN and the odometer reading, and then verify the correct date/time.
5. Select the Mode Menu. Then select Honda Systems.
6. From the System Selection Menu screen, select PGM FI.
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, IP 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 A: EGR VALVE REPLACEMENT.
^ If the EGR LIFT graph follows the EGR L COMMAND graph, the EGR valve is OK. Continue with normal troubleshooting procedures.
16. Clear any DTCs with the HDS.
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