Acura Service Bulletin 00-004
Date: December 17, 2001
Applies To: 1999 Acura 3.2TL – ALL
3.2TL Warranty Extension: EGR Port Clogging
Supersedes 00‑004, dated October 26, 2001
Background
In some regions of the U.S., certain chemical properties of gasoline may cause the intake manifold EGR port to clog or the EGR valve to fail. When this occurs, the MIL may illuminate with DTC P0401 (insufficient EGR flow) or P1491 (insufficient EGR lift).
Warranty Extension Information
This warranty extension cancels the previous PCV hose routing Product Update Campaign. Do not install the PCV hose routing kit anymore.
American Honda is extending warranty coverage for EGR system issues to 8 years or 80,000 miles, whichever comes first. To qualify, the MIL must be on with one of the listed DTCs. Install the EGR pipe kit and file a claim per this bulletin.
Customer Notification
Owners of early‑production 1999 TLs (first ~25,000 VINs) will receive letters explaining the cancellation of the PUD and the new warranty extension. Remaining 1999 TL owners will receive similar letters. Examples of these letters appear at the end of this bulletin.
Corrective Action
Clean the EGR port and install the EGR pipe kit.
Parts Information
EGR Pipe Kit: P/N 06175‑P8E‑A00
Tool Information
EGR Pipe Installation Kit: T/N 07ZAD‑P8AA000
Kit Includes:
EGR Pipe Installation Tool – T/N 07ZAD‑P8AA100
Drill Bit – T/N 07ZAH‑P8AA100
Warranty Claim Information
| Operation Number: | 120123 |
| Flat Rate Time: | 1.5 hours |
| Failed Part: | P/N 17100‑P8F‑A00 |
| Defect Code: | 537 |
| Contention Code: | L40 |
| Template ID: | 00‑004B |
| Skill Level: | Repair Technician |
Out of warranty: Repairs may qualify for goodwill consideration with prior approval.
Repair Procedure
1. Remove the intake manifold cover. Unplug the rear bank ignition coil 3P connectors and remove the rear ignition coil cover.
2. Disconnect the brake booster vacuum hose and the vacuum hose from the intake manifold.
3. Remove the throttle body (two nuts, two bolts). Leave all hoses and connectors attached. Discard the old gasket.
4. Remove the PCV valve. Remove the intake manifold (three nuts, six bolts).
5. Remove the end plates, IAT sensor, and boost plate. Retain all gaskets and O‑rings.
6. Cover the six ports on the bottom of the manifold with duct tape.
7. Use an 8 mm drill bit and carb cleaner to clean the EGR port by hand.
8. Coat the special drill bit with clean engine oil.
9. Insert the guide into the EGR port and drill through using steady pressure.
10. Remove aluminum chips and duct tape.
11. Thoroughly wash the manifold (EGR port, throttle body opening, runners). Dry with compressed air.
12. Insert the EGR pipe into the port.
13. Use the installation tool and a small hammer to drive the pipe in until flush.
14. Reinstall end plates (12 N·m), IAT sensor (18 N·m), and boost plate (12 N·m). Reinstall PCV hose if applicable.
15. Inspect and clean the EGR port in the injector base if clogged.
16. Disconnect the 6P connector and remove the EGR valve.
17. Install the new EGR valve with a new gasket (22 N·m). Reconnect the 6P connector.
18. Install the intake manifold with the original gasket. Torque bolts to 22 N·m in sequence.
19. Install the PCV valve.
20. Install the throttle body with a new gasket (22 N·m).
21. Reconnect vacuum hoses, ignition coil connectors, and covers.
22. Connect the PGM Tester and clear DTCs.
23. Override two‑trip detection:
1. Honda Systems → 2. SCS
24. Test‑drive the vehicle to confirm no new DTCs.
Customer Letter Examples
Two sample letters (for early and late 1999 TL owners) are included in the bulletin. These letters explain the cancellation of the PCV update and the new 8‑year/80,000‑mile EGR system warranty extension.
