Fuel Fill Cap Binds and Possible MIL Comes On With DTC P1456
Contents
1. HONDA Service Bulletin 04 002 Applies To See VEHICLES AFFECTED February 13 2004 Fuel Fill Cap Binds and Possible MIL Comes On With DTC P1456 Supersedes 04 002 dated January 30 2004 SYMPTOM PARTS INFORMATION The fuel fill cap is binding and if not tightened fully Fuel Fill Pipe may cause the MIL to come on and DTC P1456 EVAP 2002 04 CR V control system leakage fuel tank system to set P N 17660 S9A A01 H C 6887210 2002 03 S2000 P N 17660 S2A A31 H C 6232854 2002 04 Insight P N 17660 S3Y A01 H C 6436919 PROBABLE CAUSE The threads in the fuel fill pipe bind on the fuel fill cap VEHICLES AFFECTED CR V 2WD WARRANTY CLAIM INFORMATION aia In warranty The normal warranty applies 2003 Japan built ALL VIN begins with JHL Description England built From VIN SHSRD6 3U100001 wns Or TCE wn nen thru 323503B Do an EVAP system function test with SHSRD6 3U100161 the HDS 2004 From VIN JHLRD6 4C000001 thru Replace the fuel fill pipe JHLRD6 4C018521 2002 04 CRV k oe a X ODEL a REPAIR PROCEDURE B 209a 310105 2002 04 Insight England built From VIN SHSRD7 3U100001 thru Failed Part P N 17660 S9A A01 SHSRD7 3U100610 H C 6887210 2004 From VIN JHLRD7 4C000001 thru Defect Code 03214 2000 Skill Level Repair Technician 2002 ALL Out of warranty Any repair performed after warranty 2003 From VIN JHMAP1 3T000001 thru expiration may be eligible for goodwi2. f the vehicle failed the test do the DTC P1456 troubleshooting in section 11 of the appropriate CR V service manual 4 2 Slide up the fuel fill pipe cover and disconnect the fuel fill pipe hoses FUEL FILL PIPE COVER Disconnect these hoses 04 002 3 of 5 3 Remove the fuel fill pipe attachment nuts Remove these nuts Install the new fuel fill pipe with the original nuts Install the fuel fill pipe hoses with the original clamps Make sure the fuel fill pipe cover is seated properly Install the trunk lining 6 Connect the HDS to the vehicle s DLC data link connector and do an EVAP function test e From the HDS main menu select Honda System e From the Honda System menu select PGM FI e From the PGM FI menu select Inspection e From the Inspection menu select EVAP Test e From the EVAP Test menu select Function Test 7 Check the results of the EVAP function test e If the vehicle passed the test return it to the customer e lf the vehicle failed the test do the DTC P1456 troubleshooting in section 11 of the 2002 04 S2000 Service Manual 4of5 REPAIR PRODECURE C INSIGHT 1 Remove the trunk lining and the cargo box See page 20 44 of the 2000 04 Insight Service Manual Remove the right trunk side bulkhead and the right side trunk shelf support TRUNK SHELF SUPPORT Remove the middle floor pan See page 20 92 of the 2000 04 Insight Service
3. Manual 04 002 4 Remove the battery inner duct and the fuel fill pipe 7 Install the new fuel fill pipe with the original nuts grommet and bolt Remove the Remove the fuel 8 Install the fuel fill pipe hoses with the original battery inner duct fill pipe grommet clamps Install the fuel fill pipe grommet 9 Reinstall all removed parts 10 Connect the HDS to the vehicle s DLC data link connector and do the EVAP function test e From the HDS main menu select Honda System e From the Honda System menu select PGM FI e From the PGM FI menu select Inspection e From the Inspection menu select EVAP Test e From the EVAP Test menu select Function Test e Follow the instructions on the screen 11 Check the results of the EVAP function test e f the vehicle passed the test return it to the 5 Slide the fuel fill pipe grommet upward Then customer pls onhsel Mie nari pipe eres e If the vehicle failed the test do the DTC P1456 6 Remove the fuel fill pipe bracket bolt and the three troubleshooting in section 11 of the 2000 04 fuel fill pipe flange nuts Insight Service Manual Remove the fuel fill pipe bracket bolt B i O z d eal a Remove the fuel fill pipe flange nuts 04 002 5 of 5
4. ll consideration by JHMAP1 31007688 the District Parts and Service Manager or your Zone 2002 03 Insight ALL Office You must request consideration and get a decision before starting work 2004 Insight From VIN JHMZE1 4T000001 thru JHMZE1 4TO000003 DIAGNOSIS CORRECTIVE ACTION Remove the fuel fill cap reinsert it then tighten it The Replace the fuel fill pipe and do an EVAP system cap should turn without resistance until its function test with the HDS O ring touches the fuel fill pipe e f the cap turns freely this service bulletin does not apply continue with normal troubleshooting e f the cap binds or drags go to REPAIR PROCEDURE 2004 American Honda Motor Co Inc All Rights Reserved ATB 26537 26859 0402 1 of 5 Skill Level CUSTOMER INFORMATION The information in this bulletin is intended for use only by skilled technicians who have the proper tools equipment R and training to correctly and safely maintain your vehicle These procedures should not be attempted by do it yourselfers and you should not assume this bulletin applies to your vehicle or that your vehicle has the condition described To determine whether this information applies contact an PERAR authorized Honda automobile dealer REPAIR PROCEDURE A CR V 5 Remove the two lower rear cross beam bolts the two fuel fill pipe bracket bolts and the fuel fill pipe gasket NOTE Make sure the fuel tank is less than half full before star
5. ting this procedure 1 Raise the vehicle on a lift and remove the left rear wheel 2 Remove the three EVAP canister mounting bolts Let the canister hang in place 3 Support the rear Suspension cross beam with a powertrain lift or commercially available jack as shown Remove the cross beam bolts 4 Disconnect the fuel fill pipe hoses from the fuel fill pipe FUEL FILL PIPE BRACKET BOLTS FUEL FILL PIPE GASKET 6 Using a pry bar move the rear cross beam down to make room to remove the fuel fill pipe PRY BAR Disconnect the fuel fill pipe hoses 2 of 5 04 002 7 Install the new fuel fill pipe the fuel fill pipe gasket REPAIR PROCEDURE B S2000 and the hoses Torque the two cross beam bolts to NOTE Make sure the fuel tank is less than half full 69 N m 51 Ib ft Reinstall the EVAP canister and befor starting this procedure the wheel 8 Connect the HDS to the vehicle s DLC data link 1 Remove the left side trunk lining connector and do the EVAP function test Remove the left e From the HDS main menu select Honda side trunk lining System e From the Honda System menu select PGM FI e From the PGM FI menu select Inspection e From the Inspection menu select EVAP Test e From the EVAP Test menu select Function Test e Follow the instructions on the screen 9 Check the results of the EVAP function test e f the vehicle passed the test return it to the customer e
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