Fuel System - Difficult Fuel Fill/Nozzle Shuts Off
NUMBER: 14-001-09 REV. AGROUP: Fuel
DATE: September 1, 2009
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT:
Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly
MODELS:
2004-2008 (CS) Pacifica
2009 (DS) Ram Truck (1500)
2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up)
2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up)
2005 - 2009 (HB) Durango
2007-2009 (HG) Aspen
2005 - 2009 (ND) Dakota
2009 (JC) Journey
2007 - 2009 (JK) Wrangler
2007 - 2009 (J1) Sebring (China CKD)
2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger
2006 - 2009 (K1) Cherokee (CKD)
2007 - 2009 (KA) Nitro
2008 - 2009 (KK) Liberty
2008 - 2009 (KK) Cherokee (International Markets)
2005-2007 (KJ) Liberty
2005 - 2007 (KJ) Cherokee (International Markets)
2005 - 2009 (LE) 300C/300C Touring (International Markets)
2005 - 2009 (LX) 300/Magnum/Charger
2007 (L2) 300 (China)
2008 - 2009 (LC) Challenger
2004 - 2009 (PT) Chrysler PT Cruiser
2007 (R2) Caravan/Voyager(CKD)
2005 - 2007 (RG) Chrysler Voyager (International Markets)
2003 - 2007 (RS) Town & Country/Caravan/Voyager
2008 - 2009 (RI) Town & Country/Grand Caravan
2008 - 2009 (RI) Town & Country/Grand Voyager (International
Markets)
2005 - 2006 (TJ) Wrangler
2005 - 2009 (WH) Grand Cherokee (International Markets)
2005 - 2009 (WK) Grand Cherokee
2006 - 2009 (XH) Commander (International Markets)
2006 - 2009 (XK) Commander
NOTE:
This bulletin applies to all vehicles equipped with a gasoline engine.
DISCUSSION:
Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle.
This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues.
DIAGNOSIS:
1. Is the vehicle a LX/LE/LC/L2?
a. Yes >> proceed to Step # 2
b. No >> proceed to Step # 4
2. Idle the vehicle 60 to 90 seconds upon stopping.
3. Does tank refill properly?
a. No >> proceed to Step # 4
b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling.
4. Disconnect the vapor recirculation tube at the fuel tank.
5. Attempt to refill fuel tank.
6. Does tank refill properly?
a. Yes >> Proceed to Step # 7
b. No >> Proceed to Step # 11.
7. Reconnect the vapor recirculation tube at the fuel tank.
8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube.
9. Attempt to refill fuel tank.
10. Does tank refill properly?
a. Yes >> Replace fuel filler tube.
b. No >> Replace the vapor recirculation tube.
11. Disconnect the control valve to EVAP canister tube at the fuel tank.
12. Reconnect the vapor recirculation tube at the fuel tank.
13. Does tank refill properly?
a. No >> Replace Fuel Tank.
b. Yes >> Proceed to
14. Reconnect the control valve to EVAP canister tube at the fuel tank.
15. Disconnect the control valve to EVAP canister tube at the EVAP canister.
16. Attempt to refill fuel tank.
17. Does tank refill properly?
a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately.
b. No >> Replace the control valve to EVAP canister tube.
POLICY:
Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.