Interior/Exhaust - Sulfur Odors in Vehicle Interior
03-091June 10, 2005
Applies To:
2003-04 Accord L4 (except vehicles equipped with mass air flow sensor) - ALL
2003-04 Accord V6 - ALL
Sulfur Smell in the Interior
(Supersedes 03-091, dated April 2, 2004, to update the information marked with the black bar and asterisks.)
SYMPTOM
Sulfur smell in the interior (smells like rotten eggs).
PROBABLE CAUSE
*Sulfur concentration in fuel, catalytic converter performance, and unsealed body seams are allowing a sulfur smell to enter the interior.*
CORRECTIVE ACTION
Replace the catalytic converter, seal the body seams, and install flap seals:
2003 Accord V6 - ALL
Replace the catalytic converter only:
2003-04 Accord L4 - ALL (except vehicles equipped with mass air flow sensor)
2004 Accord V6 - ALL
NOTE:
Do not replace the catalytic converter or do any body sealing on vehicles with a mass air flow sensor. These vehicles use a different type of catalytic converter. Installing the wrong catalytic converter may result in the MIL coming on or the vehicle failing an emissions test.
PARTS INFORMATION
Catalytic Converter
L4: P/N 18160-RAA-S00, H/C 7698939
V6: P/N 18160-RCA-S00, H/C 7701550
Pre-Chamber Gasket
L4: P/N 18393-SH3-S00, H/C 3228806
V6: P/N 18393-SDB-A00, H/C 7245194
L4 and V6: P/N 18302-SP0-003, H/C 3647914
Self-Locking Nuts (6 required):
P/N 90212-5A5-003, H/C 1169812
REQUIRED MATERIALS
3M Ribbon Sealer: 3M P/N 08612 (One roll repairs 5 vehicles)
Flap Seal:
P/N 90856-56M-305, H/C 7623697
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Failed Part: P/N 18160-RCA-A00
H/C 7133234
Defect Code: 07408
Symptom Code: 06006
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. L4 Models: Remove the secondary heated oxygen sensor (SH025) from the catalytic converter, and unclip the wire harness from the exhaust heat shield. V6 Models: Remove the three-way catalytic converter.
2. Discard the six self-locking nuts and the gaskets.
3. Remove the exhaust heat shield from the catalytic converter.
4. Install the heat shield and the new catalytic converter with new exhaust gaskets and self-locking nuts. Torque the nuts to 33 N.m (25 lb-ft).
5. L4 models: Reinstall the SH02S.
6. Remove the rear bumper face, the absorber, and the beam. (See pages 20-182 and 20-183 of the 2003-05 Accord Service Manual.)
7. Degrease the outer rear panel seams.
8. Using rubber gloves, apply ribbon sealer across the bottom outer trunk floor up to the taillight panel seam.
9. Apply ribbon sealer around the seams on each side of the frame ends.
^ 2-door: Go to step 15.
^ 4-door: Go to step 10.
10. Remove both rear inner taillights. (See page 22-177 and 22-178 of the 2003-05 Accord Service Manual.)
11. Apply ribbon sealer around each of the six inner taillight mounting holes on the left and right sides. Use a small amount of sealer around each hole, and be careful to not get the sealer in the bolt holes.
12. Apply ribbon sealer to each of the two upper drain holes above the inner taillights.
13. Remove the left and right side rear trunk panels, the trunk rear trim, and the spare tire lid. (See page 20-112 and 20-113 of the 2003-05 Accord Service Manual.)
14. Cover the 20 mm hole on the right side of the rear frame with ribbon sealer.
15. Use a clean shop towel to clean the lower trunk lid drain holes.
16. 4-door only Cut four 20-mm-long strips of flap seal.
2-door only Cut two 20-mm-long strips of flap seal. Trim 5 mm off the top (adhesive) side of the flap seal, and trim 7 mm off the (non-adhesive) side.
17. Apply the flap seal over the drain hole, making sure the non-adhesive part is covering the drain hole and the adhesive part is on the lid.
18. Replace any broken trunk side panel retaining clips with new ones. Make sure the trunk lid weatherstrip is not deformed and is fully set onto the body.
19. Reinstall all removed parts.
Disclaimer