NHTSA ID Number: 10215508
Manufacturer Communication Number: A20-056
TSB/Document Date: 2022-07-07
Summary
Service bulletin - The MIL comes on with DTC P2422 (EVAP canister vent shut valve stuck closed malfunction). Dirt may be clogging the EVAP canister vent tube.
1201Q7
1201Q6
1201Q7
1205A5
1201Q6
1201Q7
1205A5
Skill Level: Repair Technician
Page 3 of 29
INSPECTION
Without Canister Filter Box
Disconnect the drain tube from the EVAP canister.
Check if there is any dust or dirt in the tube by visually inspecting and tapping/shaking it.
•
•
•
2WD models: If the drain tube has any dust or dirt inside it, go to REPAIR PROCEDURE A.
AWD models: If the drain tube has any dust or dirt inside it, go to REPAIR PROCEDURE B.
If there is no dust or dirt inside the drain tube, this bulletin does not apply. Continue with normal system
troubleshooting.
With Canister Filter Box
Disconnect drain tube C from the canister filter box.
Check if there is any dust or dirt in the tube by visually inspecting and tapping/shaking it.
•
•
All models: If there is dust or dirt inside the drain tube, go to REPAIR PROCEDURE C.
If there is no dust or dirt inside the drain tube, this bulletin does not apply. Continue with normal system
troubleshooting.
Page 4 of 29
REPAIR PROCEDURE A
Pilot Only: Using the appropriate tools in the vehicle, lower the spare tire to the ground, and remove it from the hoist
cable.
NOTE: Do not use power tools.
Disconnect the quick-connect fitting, hoses, and connectors from the EVAP canister.
Remove and reuse the EVAP canister bolt on the driver's side, then slide the canister toward the driver's side to
remove it from the vehicle.
Remove the crossmember center brace and flange bolts. Do not reuse them. Replacement parts and hardware are
included in the canister drain kit.
Page 5 of 29
Remove the rear left subframe stay and flange bolts. Do not reuse them. Replacement parts and hardware are
included in the canister drain kit.
Remove the drain tube and drain tube joint connected to the frame rail. Do not reuse the drain tube or drain tube joint.
Disconnect the rear subframe harness from the crossmember.
Page 6 of 29
Clean the surrounding area with isopropyl alcohol and cover the hole with the 30 mm door hole seal (P/N 91619-SE0000) included in the canister drain kit.
Cut the yellow harness band off the rear subframe harness. Make sure you do not damage the harness.
Loosely install the new crossmember center brace (P/N 75647-TZ5-A01) and canister filter bracket A (P/N 17316-TG7A30) as shown. Make sure canister filter bracket A is between the 8 x 22 mm bolt (P/N 90162-S09-000) and the
crossmember center brace. Use the 8 x 23.5 mm bolts (P/N 90101-SE3-003) and paint cutting M6 nuts (P/N 90361TZ5-A00) included in the canister drain kit.
Page 7 of 29
NOTE:
• Tighten the hardware by hand. You will torque them to specification in a later step.
• Make sure canister filter bracket A is routed above the hoses.
• Attach canister bracket A as shown.
Loosely install the new rear left subframe stay (P/N 50378-TG7-A02). Make sure canister filter bracket A is between
the flange bolt (P/N 90161-SHK-A00) and the rear left subframe stay as shown.
Install a new harness band (P/N 91507-SNA-003) included in the canister drain kit, and attach it to the rear left
subframe stay as shown.
Install a new grommet (P/N 91603-TG7-A02) included in the canister drain kit as shown.
Page 8 of 29
Tighten the new flange bolts to the specified torque:
•
•
Torque the 14 x 144 mm bolt (P/N 90161-S3N-000) to 132 N•m (97 lb-ft).
Torque the 12 x 30 mm bolts (P/N 90161-SHJ-A00) to 64 N•m (47 lb-ft).
Torque the crossmember center brace bolts to 19-25 N•m (14-18.4 lb-ft), and torque the nuts to 6.9-12 N•m (5.1-8.9
lb-ft).
Page 9 of 29
Unclip the rear subframe sub-harness and install the spring nut (P/N 74103-TZ5-A01) included in the canister drain kit.
NOTE:
•
The bracket on the Passport is different; this does not affect the repair procedure process.
•
The photos shown below show the Pilot bracket, along with a line drawing of a Passport braker for reference.
Pilot Model Shown
Cut the subharness band clip off the harness. Make sure you do not damage the harness.
Loosely install the new sub-harness band clip on the sub-harness as shown.
Page 10 of 29
Loosely install canister filter bracket B (P/N 17317-TG7-A30) using the 6 mm bolt (P/N 93405-0602004) included in the
kit, and attach the sub-harness band clip as shown.
Torque the 6 mm bolt to 9.4 N•m (6.9 lb-ft). Tighten the sub-harness band clip and cut off the excess band.
Page 11 of 29
Transfer the original EVAP canister vent shut valve and vent pressure sensor to the new EVAP canister.
NOTE: Do not reuse the original O-rings and quick-connect retainer.
Install the new EVAP canister. Torque the bolt to 9.4 N•m (6.9 lb-ft).
Connect the quick-connect fitting, hoses, and connectors to the EVAP canister.
Attach the drain tube joint (P/N 17742-SWA-A01) to drain tube C (P/N 17745-TG7-A30) included in the canister drain
kit as shown.
Page 12 of 29
Line up the paint dot on the drain tube C with the tab on the drain tube joint.
Connect the drain tube and drain tube joint assembly to its original location in the frame rail.
Connect drain tube A (P/N 17743-TG7-A30) to the EVAP canister. Make sure the paint dot on the drain tube is lined up
with the tab on the evap canister.
Install the new canister filter box to canister bracket A. Use two 6 mm flange nuts (P/N 94050-06040) included in the
canister kit, and torque them to 9.4 N•m (6.9 lb-ft).
Page 13 of 29
Connect drain tube A to the port labeled CANISTER on the canister filter box. Connect drain tube C to the port labeled
AIR on the canister filter box.
Line up the paint dot with the tab on the canister filter box.
Attach drain tube clips (P/N 91595-SCV-A01) included in the canister filter kit to canister bracket B as shown. Then,
attach drain tubes A and C to the drain tube clips.
Page 14 of 29
Attach drain tube C to drain tube A with the new drain tube clip.
NOTE:
•
•
The clip should line up with the painted line on drain tube A.
The paint dot on drain tube C should be visible and centered inside the clip.
Lower the vehicle to the ground.
Before raising the spare tire back into the vehicle, make sure the spare tire hoist bracket is centered in the hub opening
of the wheel.
Pilot Only: Raise the spare tire. If the bracket is correctly positioned, the spare tire will be close to level as it is raised. If
the bracket is not correctly positioned, the spare tire will not be level as it is raised and will not seat flush under the
vehicle.
Using the appropriate tools in the vehicle, tighten the spare tire hoist until it clicks. Failure to do this can result in noise
and/or damage to the hoist cable.
NOTE: Do not use power tools.
Return the tools to their correct storage areas in the vehicle.
Connect the i-HDS to the vehicle. Clear any associated DTCs, then do the EVAP function test.
•
•
If the EVAP function test passes, the repair is complete.
If the EVAP function test fails, continue with normal system troubleshooting.
Page 15 of 29
REPAIR PROCEDURE B
Pilot Only: Using the appropriate tools in the vehicle, lower the spare tire to the ground, and remove it from the hoist
cable.
NOTE: Do not use power tools.
Pilot Only: Unclip the exhaust hangers and support on the suspension control arm.
Passport Only: Remove the center exhaust and leave rear mufflers installed.
Support the rear differential with a transmission jack, and remove the four rear differential front mounting bracket flange
bolts and the two rear differential rear mount flange bolts.
NOTE: Do not reuse the differential mounting flange bolts.
Lower the rear differential about 3 in (76.2 mm).
NOTE: Make sure you do not stretch the rear differential wiring harness.
Passport Only: Disconnect the two breather hoses on top of the differential.
Disconnect the quick-connect fitting, hoses, and connectors from the EVAP canister.
Page 16 of 29
Remove and reuse the EVAP canister bolt on the driver's side, then slide the canister toward the driver's side to
remove it from the vehicle.
Remove the crossmember center brace and flange bolts. Do not reuse them. Replacement parts and hardware are
included in the canister drain kit.
Remove the rear left subframe stay and flange bolts. Do not reuse them. Replacement parts and hardware are
included in the canister drain kit.
Remove the drain tube and drain tube joint connected to the frame rail. Do not reuse the drain tube or drain tube joint.
Page 17 of 29
Disconnect the rear subframe harness from the crossmember.
Clean the surrounding area with isopropyl alcohol and cover the hole with the 30 mm door hole seal (P/N 91619-SE0000) included in the canister drain kit.
Cut the yellow harness band off the rear subframe harness. Make sure you do not damage the harness.
Page 18 of 29
Loosely install the new crossmember center brace (P/N 75647-TZ5-A01) and canister filter bracket A (P/N 17316-TG7A30) as shown. Make sure canister filter bracket A is between the 8 x 22 mm bolt (P/N 90162-S09-000) and the
crossmember center brace. Use the 8 x 23.5 mm bolts (P/N 90101-SE3-003) and paint cutting M6 nuts (P/N 90361TZ5-A00) included in the canister drain kit.
NOTE:
• Tighten the hardware by hand. You will torque them to specification in a later step.
• Make sure canister filter bracket A is routed above the hoses.
• Attach canister bracket A as shown.
Page 19 of 29
Loosely install the new rear left subframe stay (P/N 50378-TG7-A02). Make sure canister filter bracket A is between
the flange bolt (P/N 90161-SHJ-A00) and the rear left subframe stay as shown.
Install a new harness band (P/N 91507-SNA-003) included in the canister drain kit, and attach it to the rear left
subframe stay as shown.
Install a new grommet (P/N 91603-TG7-A02) included in the canister drain kit as shown.
Tighten the new flange bolts to the specified torque:
•
•
Torque the 14 x 144 mm bolt (P/N 90161-S3N-000) to 132 N•m (97 lb-ft).
Torque the 12 x 30 mm bolts (P/N 90161-SHJ-A00) to 64 N•m (47 lb-ft).
Page 20 of 29
Torque the crossmember center brace bolts to 19-25 N•m (14-18.4 lb-ft), and torque the nuts to 6.9-12 N•m (5.1-8.9
lb-ft).
Unclip the rear subframe subharness and install the spring nut (P/N 74103-TZ5-A01) included in the canister drain kit.
NOTE:
•
The bracket on the Passport is different; this does not affect the repair procedure process.
•
The photos below show the Pilot bracket, along with a line drawing of a Passport bracket for reference.
Pilot Model Shown
Cut the subharness band clip off the harness. Make sure you do not damage the harness.
Page 21 of 29
Loosely install the new subharness band clip on the subharness as shown.
Loosely install canister filter bracket B (P/N 17317-TG7-A30) using the 6 mm bolt (P/N 93405-0602004) included in the
kit, and attach the subharness band clip as shown.
Page 22 of 29
Torque the 6 mm bolt to 9.4 N•m (6.9 lb-ft). Tighten the subharness band clip and cut off the excess band.
Transfer the original EVAP canister vent shut valve and vent pressure sensor to the new EVAP canister.
NOTE: Do not reuse the original O-rings and quick-connect retainer.
Install the new EVAP canister. Torque the bolt to 9.4 N•m (6.9 lb-ft).
Connect the quick-connect fitting, hoses, and connectors to the EVAP canister.
Page 23 of 29
Attach the drain tube joint (P/N 17742-SWA-A01) to drain tube C (P/N 17745-TG7-A30) included in the canister drain
kit as shown.
Make sure the paint dot on drain tube C is lined up with the tab on the drain tube joint as shown.
Connect the drain tube and drain tube joint assembly to its original location in the frame rail.
Connect drain tube A (P/N 17743-TG7-A30) to the EVAP canister. Make sure the paint dot on the drain tube is lined up
with the tab on the evap canister.
Page 24 of 29
Install the new canister filter box to canister bracket A. Use two 6 mm flange nuts (P/N 94050-06040) included in the
canister kit, and torque them to 9.4 N•m (6.9 lb-ft).
Connect drain tube A to the port labeled CANISTER on the canister filter box. Connect drain tube C to the port labeled
AIR on the canister filter box.
Make sure the paint dot is lined up with the tab on the canister filter box.
Page 25 of 29
Attach drain tube clips (P/N 91595-SCV-A01) included in the canister filter kit to canister bracket B as shown. Then,
attach drain tubes A and C to the drain tube clips.
Attach drain tube C to drain tube A with the new drain tube clip as shown.
NOTE:
•
•
The clip should line up with the painted line on drain tube A.
The paint dot on drain tube C should be visible and centered inside the clip.
Page 26 of 29
Install the rear differential in the reverse order of removal. Torque the new front bracket flange bolts to 49 N•m (36 lbft). Torque the new rear mount flange bolts to 69 N•m (51 lb-ft).
Install the exhaust pipe and muffler. Refer to the service information.
NOTE:
•
Do not reuse the exhaust gasket and flange nuts.
•
(Pilot Only) Clip the exhaust back into the exhaust hangers.
Lower the vehicle to the ground.
Before raising the spare tire back into the vehicle, make sure the spare tire hoist bracket is centered in the hub opening
of the wheel.
(Pilot Only) Raise the spare tire. If the bracket is correctly positioned, the spare tire will be close to level as it is raised.
If the bracket is not correctly positioned, the spare tire will not be level as it is raised and will not seat flush under the
vehicle.
Using the appropriate tools in the vehicle, tighten the spare tire hoist until it clicks. Failure to do this can result in noise
and/or damage to the hoist cable.
NOTE: Do not use power tools.
Return the tools to their correct storage areas in the vehicle.
Connect the i-HDS to the vehicle. Clear any associated DTCs, then do the EVAP function test.
•
•
If the EVAP function test passes, the repair is complete.
If the EVAP function test fails, continue with normal system troubleshooting.
Page 27 of 29
REPAIR PROCEDURE C
NOTE:
• Do this procedure only if the canister filter box has already been installed and needs to be replaced because of
dust or dirt contamination.
• If the dots are no longer visible on the tubes, mark them with a paint dot to make sure they are installed correctly
on the new canister filter box.
Disconnect drain tube A from the canister filter box.
Remove and replace the canister filter box (P/N 17315-TM8-L01). Reuse the two flange nuts, and torque them to 9.4
N•m (6.9 lb-ft).
Page 28 of 29
Connect drain tube A to the port labeled CANISTER on the canister filter box. Connect drain tube C to the port labeled
AIR on the canister filter box.
Make sure the paint dot is lined up with the tab on the canister filter box.
Connect the i-HDS to the vehicle. Clear any associated DTCs, then do the EVAP function test.
•
•
If the EVAP function test passes, the repair is complete.
If the EVAP function test fails, continue with normal system troubleshooting.
END
Page 29 of 29
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TSB/Document ID: A20-056
Replacement Service Bulletin Number:
MFR Communication Date: 2022-06-30
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
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