Emissions - MIL ON/DTC's P0441/P0442/P0455/P0456 Set

20 09 01

October 13, 2009

2013354 Supersedes T.B. Group 20 number 08-04 dated Jul. 17, 2008 due to
updated EVAP canister part number.





Vehicle Information

Condition

MIL ON, DTCs P0441, P0442, P0455 or P0456 Stored in ECM Fault Memory





MIL ON with one or more of the following DTCs are stored in ECM fault memory:

Note:
Vehicle may come from two different manufacturing facilities (designated by "E" or "P" in the VIN). The range varies from each factory.

Technical Background

The above faults related to the Evaporative Emission (EVAP) system may be due to charcoal contamination from the charcoal canister to the EVAP canister purge regulator valve -N80-.

Production Solution

A redesigned charcoal canister has been installed in production with improved charcoal filtering as of:

^ 3C_7P045145 (sedan)

^ 3C_7E051588 (sedan and wagon)

Service

If any of the DTCs listed above are stored in the ECM fault memory:

^ Follow Guided Fault Finding to determine root cause of DTC(s).

^ Perform all related technical bulletins that apply.

^ Perform emission system leak test as described in the Repair Manual Group 20, Fuel Supply, Evaporative Emission (EVAP) system, checking for leaks in ElsaWeb.

If during diagnosis a leak is identified at the -N80- Purge Valve due to charcoal contamination from the canister, follow instruction below.





^ Raise and support vehicle.

^ Remove right rear wheel housing liner, see Repair Manual Body Exterior Group 66 Exterior equipment, "Rear wheel housing liner, removing and installing" in ElsaWeb.

^ Disconnect T-3 electrical connector at Leak Detection Pump (LDP).

^ Disconnect EVAP purge line, EVAP vacuum Line and EVAP vent line from EVAP canister.





Remove EVAP canister.

Tip:

Remove canister assembly from inner fender by pulling assembly downwards and out after fastener removal.

Note:

Observe EVAP canister part number, DO NOT replace canister if part number has a "C" index unless a technical issue is identified.

If vehicle is equipped with a "C" index:

^ Continue to "Cleaning EVAP System".

If vehicle IS NOT equipped with a "C" indexed EVAP canister:

^ Continue to Separate LDP from Canister.





SEPARATE LDP FROM CANISTER:

^ Remove the LDP pump fasteners from the back of the LDP pump.

^ Remove canister line hose clamp.

^ Remove LDP filter fastener.

Tip:
Spring type clamp pliers VAS 5024A are recommended for removing and installing spring clamps. Always replace tensioning clamps with spring type clamps.

Always replace tensioning clamps with spring type clamps.

CLEANING EVAP SYSTEM





^ Remove EVAP canister purge regulator valve -
N80-, see Repair Manual Group 20 Fuel supply,
gas operation, EVAP canister system in
ElsaWeb.





^ Disconnect EVAP line at bulkhead connection.

^ Using a regulated air supply (no greater than 90PSI), blow air through the EVAP purge line to remove any potential particulates or contaminants in line.





^ Repeat process in the other direction at EVAP vent line after bulkhead.

Assembly





Note:
Vent hose Part No. 8P0133781B is clearly marked to ensure correct installation.

Slide hose onto pipe and valve, at a minimal, up to painted white line on hose before clamping.

Ensure new vent hose is not bent, twisted or chaffing other components.

Tip:

Spring type clamp pliers VAS 5024A are recommended for removing and installing spring clamps. Always replace tensioning clamps with spring type clamps.

^ Install new EVAP canister purge regulator valve -N80- Part No. 06E 906 517A and inspect and ensure installation of new -N80- valve vent hose Part No. 8P0 133 781B. Secure new vent valve hose with spring clamps Part No. N10199201. See Repair Manual Group 20 Fuel supply, gas operation, EVAP canister system in ElsaWeb.

^ Install LDP pump on new EVAP canister, Part No. 3C0 201 797 D in reverse order of removal.

^ Install EVAP canister in reverse order of removal. Tighten fasteners to 10 Nm (89 in. lbs.).

^ Install right rear wheel housing liner, see Repair Manual Body Exterior Group 66 Exterior equipment, "Rear wheel housing liner, removing and installing" in ElsaWeb.

^ Clear codes and reset readiness code.





Warranty





Required Parts and Tools

Additional Information

All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.