Emissions - MIL ON/DTC P0440/P0455 (EVAP) Set

VOLUME
1

GROUP
Fuel System

NUMBER
002

MODEL
Sephia

DATE
July, 1997

SUBJECT:
Sephia Fuel Tank Pressure Sensor Relocation





This bulletin provides information related to a change in the location of the Fuel Tank Pressure Sensor (FTPS) in Sephia model's equipped with the BP DOHC (1.8 Liter) engine. 1997 Sephia models, beginning with VIN KNAFA1257V5312880 (production date 6/2/97), are equipped with the relocated FTPS and related vapor hoses.

Some 1996 and 1997 Sephia models have experienced repeat occurrences of "Check Engine" Light illumination where a Diagnostic Trouble Code (DTC) P0455 Evaporative Emission Control System - Gross Leak Detected (1997 models) or DTC P0440 - Evaporative Emission Control System Malfunction (1996 models) was retrieved. In many instances, the cause of the DTC's has been liquid fuel collecting in the vapor hoses between the fuel tank rollover valves and the FTPS. When fuel collects in the vapor hoses, the system pressure that the FTPS monitors at the start of the Evaporative Emission System Purge Leak Check can be momentarily incorrect, resulting in "Check Engine" Light illumination.

To reduce the possibility of liquid fuel collecting in the FTPS vapor hoses, the FTPS has been relocated to a position higher than the level of the fuel tank rollover valves and the related vapor hoses have been changed.

SEPHIA FUEL TANK PRESSURE SENSOR RELOCATION:

Confirm that the vehicle is a 1996 or 1997 Sephia equipped with the 1.8 Liter engine and has a production date prior to 6/2/97 (VIN KNAFA1257V5312880).

Confirm that the DTC P0455 or P0440 is caused by liquid fuel collecting in the Fuel lank Pressure Sensor vapor hoses.

NOTICE
Check for liquid fuel in the Fuel lank Pressure Sensor vapor hoses. If no fuel is found in the Fuel lank Pressure Sensor vapor hoses, use the diagnostic procedures in the Sephia Service Manual to determine the cause of the DTC P0455 or P0440.

Review "Replacement Procedures" before attempting Fuel lank Pressure Sensor relocation. Inspect all replacement parts for damage prior to installation.

PARTS LIST: REQUIRED TOOLS:

^ Vapor Hose Assembly ^ 3/8" Drive Rachet
(0K2YT 74 91X)

^ Vent Hose - Fuel Tank ^ 3/8" Drive 10" Extension
Pressure Sensor (0K29T 42 548C)

^ Mounting Bracket - Fuel Tank ^ Pliers
Pressure Sensor (0K29T 18 215)

^ Foot-Pound Torque Wrench

^ 14 mm Socket

^ 10 mm Socket

REPLACEMENT PROCEDURE:





1. Carefully lower the fuel tank approximately one inch by loosening the fuel tank strap mounting bolts.

CAUTION
Do not loosen the fuel tank strap mounting bolts more than one inch.





2. Remove the vapor separator hose where it is connected to the fuel filler pipe vapor separator line.





3. Disconnect the Fuel Tank Pressure Sensor electrical connector.

4. Remove the Fuel Tank Pressure Sensor from its mounting bracket, then disconnect the vapor and vent hoses.

NOTICE
Discard the vent hose after removal.





5. Disconnect the hoses from the fuel tank rollover valves then remove and discard the vapor hose assembly from the vehicle.





6. Remove (and keep) the bolt securing the Fuel Tank Pressure Sensor mounting bracket to the crossmember, then remove and discard the mounting bracket.





7. Install the new vapor hose assembly by first connecting the hoses to the rollover valves.

NOTICE
It is not necessary to remove the fuel tank to connect the vapor hose harness to the rollover valves.





8. Install the Fuel Tank Pressure Sensor onto the new mounting bracket.

9. Connect the new vapor hose to the Fuel Tank Pressure Sensor.

10. Re-connect the Fuel Tank Pressure Sensor electrical connector.

11. Install the Fuel Tank Pressure Sensor mounting bracket onto the threaded hole in the floor pan crossmember using the existing Fuel Tank Pressure Sensor mounting bracket bolt removed in Step 6.

12. Connect the new vent hose to the Fuel Tank Pressure Sensor and insert the end of the hose into the hole in the top of the suspension crossmember.





13. Connect the vapor separator hose to the fuel filler pipe vapor separator line.

NOTICE
Secure the vapor separator hose to the fuel filler and vent hoses using the existing tie-wrap.





14. Tighten the fuel tank strap mounting bolts.

Tightening Torque:
27-38 ft-lb (37-52 N.m)

Affected Production Range:

1996 and 1997 Sephia models equipped with the 1.8 Liter engine with a production date prior to 6/2/97 (VIN KNAFA1257V5312880).





Part Number Information





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