Emissions/Fuel Systems - Difficulty Filling Fuel Tank
No: 19/04/03/NASRef:
Issue: 1
Date: 12/05/03
Trickle Valve Replacement Procedure
AFFECTED VEHICLE RANGE:
Discovery (LT) All
SITUATION:
MIL ILLUMINATION OR DIFFICULTY FILLING FUEL TANK
The customer may complain of difficulty adding fuel to the tank due to the fuel delivery cut off. The MIL may also be illuminated because of Diagnostic Module Test Leakage (DMTL) pressure leakage can result in fault codes P0455 or P0446 logged. The cause of these events may be a faulty or leaking trickle valve. The trickle valve has not previously been available for service repairs.
RESOLUTION:
INSPECT AND IF INDICATED REPLACE TRICKLE VALVE
Should a customer complain of the premature shut-off symptom or MIL illumination with the P0455/P0446 fault codes, follow the leak test procedure below and if indicated replace the trickle valve.
PARTS INFORMATION:
VUB502530 Trickle valve Kit Qty 1
AS400 WARRANTY CLAIMS (CANADA ONLY)
17.90.02/01 Time 0.70 hrs.
Perform Evaporative Leak Test
19.55.31 Time 0.70 hrs.
Install trickle valve
17.90.89/26 Time 0.20 hrs
Perform TestBook/T4 DMTL test
FAULT CODE: Y
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
LEAK TEST
NOTE:
Applying a soapy solution to the trickle valve when the system is pressurized may assist with the diagnosis and confirm the source of the leak.
1. Using service tool LRA-19-005A (Evaporative Emissions System Tester) establish if the leak is coming from around the anti-trickle valve.
2. If the leak is coming from the anti-trickle valve, refer to the replacement procedure.
3. If the leak is not coming from around the anti-trickle valve then further investigation will be required. This repair procedure does not apply.
REPLACEMENT OF ANTI-TRICKLE LEAK
1. Refer to RAVE section 19.55.07 and remove the fuel filler tube.
2. Remove the two hose clamps securing the vent pipes to the trickle valve. (A in Figure 1)
CAUTION:
Removal of the locking screw and careful attention to the clockwise release of the trickle valve nut are required to avoid damage to the filler neck assembly.
3. Remove the trickle valve M4 locking screw. (B in Figure 1)
4. Unscrew the M22 nut clockwise and remove the trickle valve.
NOTE:
Figure 2 illustrates the correct orientation of the trickle valve. The vent pipes must be angled at approximately 45° to the center of the fuel filler tube.
5. Install the new trickle valve and O-ring.
6. Tighten the nut to 3 to 4 Nm (2.2 to 2.9 lbf.ft).
7. Install the trickle valve locking screw and tighten to 1.5 to 1.8 Nm (1.1 to 1.3 lbf.ft).
8. Install the vent pipes to the trickle valve and secure with the new hose clamps supplied in the kit.
9. Connect TestBook/T4 to the vehicle and load disc Archive 21 or later.
10. Follow the on-screen instructions and select "Diagnostic System".
11. Clear any fault codes.
12. Follow the on-screen instructions and select "Petrol Engine".
13. Follow the on-screen instructions and select "Sub System Test".
14. Follow the on-screen instructions and select "Evaporative Leak" to carry out the DMTL test.
15. After the test is complete check for any fault codes to ensure no further problems exist.