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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:
|
TOY220036 | 1 | 9 |
| 2 | CAN Interface Module Kit*
NOTE:
|
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
- 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.
- Replace the Fuel Tank Filler Pipe Sub-assembly with the updated part.
- 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.
- 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
- 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
- 2003 or 2004 model year Corolla Repair Manual:
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