MIL ON - DTC P0401 EGR Flow Insufficient
99-038August 31, 1999
Applies To:
1998-99 Accord V6 - 4-door thru VIN 1HGCG1...XA015172
- 2-door thru VIN 1 HGCG2...XAO10767
MIL Is On With DTC P0401
SYMPTOM
The MIL is on and DTC P0401 (Insufficient EGR Flow) is set.
PROBABLE CAUSE
The EGR port in the intake manifold is clogged.
CORRECTIVE ACTION
Clean the EGR port. Replace the intake manifold chamber and the PCV hose.
BACKGROUND and FUTURE ACTION
Certain basic chemical properties of gasoline (regardless of brand) may cause the EGR port in the intake manifold to clog. This service bulletin is being issued to repair customer vehicles that develop this problem now.
American Honda is preparing a Product Update Campaign (PUD) that will be launched in the Fall of 1999. To provide a record of which vehicles have been repaired between now and the start of the PUD, and to avoid duplicate repairs, make sure you center-punch the VIN in the engine compartment and file the proper warranty claim. The repair activity for the PUD will be different than the repair procedure in this service bulletin. Do not start updating vehicles at this time. Please wait for the PUD announcement.
When the PUD starts, your dealership will be allocated a 25% to 30% parts supply prior to customer notification. Do not stockpile parts now. Parts will be available only through the Controlled Parts Ordering System.
In summary:
^ Use this procedure and these parts to fix vehicles that come in with a DTC P0401.
^ By using this procedure, duplicate repairs will be prevented.
^ Wait for the PUD to be announced. Do not campaign vehicles that have not failed; we will send you a new service bulletin with a new procedure at that time.
PARTS INFORMATION
Intake Manifold Chamber B Kit:
P/N 06170-P8A-A10, H/C 6149546
(kit contains one intake manifold chamber, one
12 mm diameter hose clamp, one 15.5 diameter
hose clamp, one PCV hose, and one PCV cap)
Throttle Body Gasket:
P/N 16176-P8A-AO1, H/C 5181417
WARRANTY CLAIM INFORMATION
In warranty: The normal warranty applies.
Operation number: 120107
Flat rate time: 2.0 hours
Failed part: P/N 171 00-P8A-A00
H/C 5232749
Defect code: 537
Contention code: K69
Template ID: 99-038A
Skill level: Repair Technician
Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. Refer to the 1998-99 Accord V6 Service Manual Supplement if needed, and remove these components:
^ Throttle body cover (see page 6-31)
^ Intake manifold covers (four total; see pages 6-31 and 6-32)
^ Ignition wire holder (see page 6-32)
^ Ignition wire cover (see page 6-32)
^ Intake air duct (see page 5-2)
^ Brake booster vacuum hose and vacuum hose (see page 5-3)
2. Remove the throttle body from the intake manifold (two nuts and two bolts). Leave all hoses and connections intact as shown. Discard the throttle body gasket.
3. Remove the PCV valve from the cylinder head cover, and remove the intake manifold (three nuts and six bolts). Place the manifold on a workbench.
4. Remove and discard the intake manifold chamber. Save the gaskets, brace, intake manifold cover brackets, and mounting hardware for reassembly.
5. Remove the PCV valve from the PCV hose. Remove the PCV hose from the intake manifold. Save one of the hose clamps for reassembly, and discard the PCV hose.
6. Use an 8-mm drill bit and carburetor cleaner to clean the EGR port in the manifold. Turn the drill bit only by hand. Do not use a power drill. After you clean the EGR port, use carburetor cleaner to thoroughly clean the inside of the manifold.
7. Check the EGR port in the front injector base on the engine for blockage. If you see any blockage, clean the EGR port.
8. Install the intake manifold cover brackets you saved in step 4 on the new intake manifold chamber.
9. Connect the new PCV hose to the PCV port on the bottom of the manifold chamber. Secure it with the new 12 mm hose clamp. Position the hose clamp with its tangs facing towards the manifold chamber.
10. Install the manifold chamber onto the manifold with the gaskets, brace, and mounting hardware you saved in step 4. Torque the bolts and nuts to 12 Nm (8.7 lb-ft).
11. Connect the new PCV hose to the PCV valve with the hose clamp you saved in step 5.
12. Install the PCV cap onto the old PCV port on the manifold. Secure it with the new 15.5 mm diameter hose clamp.
13. Reinstall the intake manifold with the original gasket. Be careful not to pinch the new PCV hose. Torque the bolts and nuts to 22 Nm (16 lb-ft) sequentially in two or three steps as shown.
14. Reinstall the throttle body onto the intake manifold with a new throttle body gasket. Torque the nuts and bolts to 22 Nm (16 lb-ft).
15. Reinstall the components removed in step 1.
16. Connect a PGM Tester with SN 900 (or higher) software, and clear any stored DTCs. Make sure the MIL has gone off and stays off.
17. Center-punch a completion mark above the second character (H) of the engine compartment VIN.
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