Chrysler RG Voyager. Manual — part 1244
DIAGNOSIS AND TESTING - VEHICLE DOES
NOT FILL
CONDITION
POSSIBLE CAUSES
CORRECTION
Pre-Mature Nozzle Shut-Off
Defective fuel tank assembly
components.
Fill tube improperly installed
(sump)
Fill tube hose pinched.
Check valve stuck shut.
Control valve stuck shut.
Defective vapor/vent components.
Vent line from control valve to
canister pinched.
Vent line from canister to vent
filter pinched.
Canister vent valve failure
(requires double failure,
plugged to NVLD and
atmosphere).
Leak detection pump failed
closed.
Leak detection pump filter
plugged.
On-Board diagnostics evaporative
system leak test just conducted.
Canister vent valve vent
plugged to atmosphere.
Engine still running when
attempting to fill (System
designed not to fill).
Defective fill nozzle.
Try another nozzle.
Fuel Spits Out Of Filler
Tube.
During fill.
See Pre-Mature Shut-Off.
At conclusion of fill.
Defective fuel handling
component. (Check valve stuck
open).
Defective vapor/vent handling
component.
Defective fill nozzle.
RS
EVAPORATIVE EMISSIONS
25 - 17
ORVR (Continued)
PCV VALVE
DESCRIPTION
The PCV valve contains a spring loaded plunger.
The plunger meters the amount of crankcase vapors
routed into the combustion chamber based on intake
manifold vacuum (Fig. 10) or (Fig. 11).
OPERATION
When the engine is not operating or during an
engine backfire, the spring forces the plunger back
against the seat. This prevents vapors from flowing
through the valve (Fig. 12).
When the engine is at idle or cruising, high mani-
fold vacuum is present. At these times manifold vac-
uum is able to completely compress the spring and
pull the plunger to the top of the valve (Fig. 13). In
this position there is minimal vapor flow through the
valve.
During periods of moderate intake manifold vac-
uum the plunger is only pulled part way back from
the inlet. This results in maximum vapor flow
through the valve (Fig. 14).
DIAGNOSIS AND TESTING - PCV SYSTEM
WARNING:
APPLY
PARKING
BRAKE
AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
OR ADJUSTMENT WITH THE ENGINE OPERATING.
(1) With engine idling, remove the hose from the
PCV valve. If the valve is not plugged, a hissing
noise will be heard as air passes through the valve. A
strong vacuum should also be felt when a finger is
placed over the valve inlet.
Fig. 10 PCV VALVE 2.4L
1 - PCV Valve
Fig. 11 PCV VALVE 3.3/3.8L
Fig. 12 Engine Off or Engine Backfire No Vapor
Flow
Fig. 13 High Intake Manifold Vacuum Minimal Vapor
Flow
Fig. 14 Moderate Intake Manifold Vacuum Maximum
Vapor Flow
25 - 18
EVAPORATIVE EMISSIONS
RS
(2) Install
hose
on
PCV
valve.
Remove
the
make-up air hose from the air plenum at the rear of
the engine. Hold a piece of stiff paper (parts tag)
loosely over the end of the make-up air hose.
(3) After allowing approximately one minute for
crankcase pressure to reduce, the paper should draw
up against the hose with noticeable force. If the
engine does not draw the paper against the grommet
after installing a new valve, replace the PCV valve
hose.
(4) Turn the engine off. Remove the PCV valve
from intake manifold. The valve should rattle when
shaken.
(5) Replace the PCV valve and retest the system if
it does not operate as described in the preceding
tests. Do not attempt to clean the old PCV valve.
If the valve rattles, apply a light coating of Loctite
t
Pipe Sealant With Teflon to the threads. Thread the
PCV valve into the manifold plenum and tighten to 7
N·m (60 in. lbs.) torque.
VAPOR CANISTER
DESCRIPTION
There are 2 EVAP canisters on the vehicle. The
vacuum and vapor tubes connect to the top of the
canister. It is a charcoal canister (Fig. 15) or (Fig.
16).
OPERATION
All vehicles use a maintenance free, evaporative
(EVAP) canister. Fuel tank vapors vent into the can-
ister. The canister temporarily holds the fuel vapors
until intake manifold vacuum draws them into the
combustion chamber. The Powertrain Control Module
(PCM) purges the canister through the proportional
purge solenoid. The PCM purges the canister at pre-
determined intervals and engine conditions.
Purge Free Cells
Purge-free memory cells are used to identify the
fuel vapor content of the evaporative canister. Since
the evaporative canister is not purged 100% of the
time, the PCM stores information about the evapora-
tive canister’s vapor content in a memory cell.
The purge-free cells are constructed similar to cer-
tain purge-normal cells. The purge-free cells can be
monitored by the DRB III
t Scan Tool. The only dif-
ference between the purge-free cells and normal
adaptive cells is that in purge-free, the purge is com-
pletely turned off. This gives the PCM the ability to
compare purge and purge-free operation.
REMOVAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the 2 hoses (Fig. 15).
(3) Remove bolt.
(4) Pull canister rearward to remove.
Fig. 15 FRONT EVAP CANISTER
1 - Front EVAP Canister
2 - Vent Valve
Fig. 16 REAR EVAP CANISTER
1 - Rear EVAP Canister
2 - Front EVAP Canister
3 - Vent Valve
RS
EVAPORATIVE EMISSIONS
25 - 19
PCV VALVE (Continued)
REMOVAL - WITH NVLD - FOLD-IN-FLOOR
(1) Raise and support the vehicle.
(2) Remove the 3 hoses.
(3) Remove bolt (Fig. 17).
(4) Pull canister rearward to remove.
REMOVAL - REAR EVAP CANISTER
(1) Raise and support the vehicle.
(2) Remove 3 hoses (Fig. 16).
(3) Remove the bolt.
(4) Pull rearward to remove canister.
INSTALLATION
INSTALLATION
(1) Install canister arrow heads into the rubber
gromments (Fig. 18)
(2) Install bolt and tighten.
(3) Install hoses.
(4) Lower vehicle.
INSTALLATION - WITH NVLD - FOLD-IN-
FLOOR
(1) Install canister arrow heads into the rubber
gromments (Fig. 19).
(2) Install bolt and tighten.
(3) Install hoses.
(4) Lower vehicle.
VAPOR CANISTER LOCATION
Fig. 17 MOUNTING BOLT
Fig. 18 FRONT EVAP CANISTER BRACKET
Fig. 19 CANISTER MOUNTING STUDS
25 - 20
EVAPORATIVE EMISSIONS
RS
VAPOR CANISTER (Continued)
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