M.I.L. “ON” DTC P0440, P0441, P0442, P0446, AND/OR P0456 – 2003-2005 Toyota Corolla & Matrix

EG051-06
August 23, 2006

 

Title:
M.I.L. “ON” DTC P0440, P0441, P0442, P0446, AND/OR P0456 — FUEL FILLER TUBE IMPROVEMENT

 

Models:
’03 – ’04 Corolla & Matrix (2WD), & ’05 Matrix (4WD)

 

Introduction

Some 2003 – 2004 Corolla and Matrix 2WD and 2005 model year Matrix 4WD vehicles may exhibit a M.I.L. “ON” condition with DTCs P0440, P0441, P0442, P0446, and/or P0456 stored. An improved fuel filler tube has been developed to correct this condition.

 

Applicable Vehicles

• 2003 – 2004 model year Corolla and Matrix vehicles equipped with 2WD.
• 2005 model year Matrix vehicles equipped with 4WD.

 

Parts Information

PREVIOUS PART NUMBER	CURRENT PART NUMBER	PART NAME	QTY
77201-02080	77201-12750	Pipe Sub-assembly, Fuel Tank Filler	1
77300-08010	Same	Cap Assembly, Fuel Tank w/Tether	1

 

Required Tools & Material

TOOLS & MATERIAL	QUANTITY
Metric Socket Set and Hand Tools	As Needed

 

Warranty Information

OP CODE	DESCRIPTION	TIME		OFP	T1	T2
EG5038	R & R Fuel Filler Tube	0.4		77201-02080	64	13

 

Applicable Warranty*: This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. For California specification vehicles sold, registered, and operated in California, Maine, Massachusetts, and Vermont, this repair is covered under the California Emission Warranty, which is 36 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date.

 

*Warranty application is limited to correction of a problem based upon a customer’s specific complaint.

 

Required SSTs

 

ITEM NO.	SPECIAL SERVICE TOOLS (SSTs)	PART NUMBER	QTY	DRW**
1	Toyota Diagnostic Tester Kit* NOTE: All components from this kit/set are required. 12 Megabyte Diagnostic Tester Program Card (P/N 01002593-005) with version 13.4a Software (or later) is required.	TOY220036	1	9
2	CAN Interface Module Kit* NOTE: All components from this kit/set are required.	01002744	1	9

 

*Essential SSTs.

**Drawer number in SST Storage System.

NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.

 

Repair Procedure

1. Using the Diagnostic Tester, check for Diagnostic Trouble Codes (DTCs). If P0440, P0441, P0442, P0446, and/or P0456 are present, inspect the fuel cap sealing surface on the Fuel Tank Filler Pipe Sub-assembly for corrosion.
   • If corrosion is present, proceed to step 2.
   • If NO corrosion is present, proceed to step 5.

2. Replace the Fuel Tank Filler Pipe Sub-assembly with the updated part.
3. Inspect the fuel cap O-ring for damage, for example, scratches or flaws on the sealing surface. If damage is present, replace the fuel cap.
4. Run the EVAP Monitor to confirm the repair. Refer to the Technical Information System (TIS):
   • 2004 model year Corolla Repair Manual: Diagnostics: SFI System (April 2003): Readiness Monitor Drive Pattern
   • 2004 model year Matrix Repair Manual: Diagnostics: SFI System (1ZZ-FE) or (2ZZ-FE) (May 2003): Readiness Monitor Drive Pattern
   • 2005 model year Matrix Repair Manual: Diagnostics: SFI System (1ZZ-FE(4WD)): Readiness Monitor Drive Pattern
5. If another EVAP system fault is present, refer to TIS and diagnose the fault accordingly:
   • 2003 or 2004 model year Corolla Repair Manual:
     • Emission Control: Emission Control System: On-Vehicle Inspection
     • Emission Control: Emission Control System: Inspection
   • 2003 or 2004 model year Matrix Repair Manual: Emission Control: Emission Control System: (1ZZ-FE) or (2ZZ-GE) On-Vehicle Inspection
   • 2005 model year Matrix Repair Manual: Diagnostics: SFI System (1ZZ-FE(4WD)): P0442, P0456 Evaporative Emission Control System Leak Detected