Emissions - On Board Refueling Vapor Recovery Valve
Date: July 2001Order No.: P-B-47.31/07
Supersedes:
Group: 47
SUBJECT:
MODEL 129, AS OF MODEL YEAR 1997 - 2000
REPLACEMENT OF ORVR (ON BOARD REFUELING VAPOR RECOVERY) PRESSURE
RELIEF VALVE
If replacement of the ORVR pressure relief valve is required, please be advised that the old valve is no longer available and has been succeeded by a new valve. Please refer to procedure below for replacement of ORVR pressure relief valve:
Procedure
1. Remove windscreen cover (A, Figure 1).
Note:
If vehicle is equipped with a CD changer proceed to step 2, if not proceed to step 3.
2. Remove CD changer and mounting bracket:
^ Remove 4 screws securing CD changer to mounting bracket, disconnect wire harnesses and remove CD changer.
^ Remove two nuts (arrows, Figure 2) and two screws (not shown) securing CD mounting bracket (A) to trunk, remove bracket.
3. Remove tail lamp covers and left/right side inner trunk panels.
4. Remove (front) inner trunk panel (A, Figure 3).
5. Remove nut (arrow, Figure 4), remove pressure relief valve cover (A).
DANGER!
Fuel or fuel vapors may be present, risk of explosion and/or injury:
^ Wear protective clothing and eye protection.
^ NO open flames/sparks, heat emitting equipment in work area.
^ Refer also to WIS AS47.00-Z-0001-01A for additional safety information.
6. Remove pressure relief valve (A, Figure 5):
^ Loosen clamps (arrows).
^ Separate hoses from valve (A).
^ Remove nut (B).
^ Remove pressure relief valve (A).
7. Remove ORVR vent pipe (A, Figure 6):
^ Pull ORVR vent pipe (A) out from mounting clips (arrows).
^ Loosen clamp (A, Figure 7), separate ORVR vent pipe (C) from vent hose (D).
^ Loosen clamp (arrow, Figure 8), separate ORVR vent pipe (A) from vent hose (B).
^ Remove ORVR vent pipe (A).
8. Loosen hose clamp (B, Figure 7) remove vent hose (D, Figure 7).
9. Remove charcoal canister (C, Figure 8 [refer to WIS AR47.30-P-8212B]).
10. Remove fuel tank partition wall (A, Figure 9):
^ Separate clips (B) from partition wall (A) and remove spare tire cover (C)
^ Remove bolts securing fuel tank partition wall (A) to vehicle body.
^ Remove ORVR vent pipe clips (arrows).
^ Loosen hose clamp (arrow, Figure 10), and remove overflow hose (A) from overflow pipe (B) discard hose.
^ Remove fuel tank partition wall (A, Figure 9) from vehicle.
11. Install new fuel tank partition wall (A, Figure 11):
^ Install insulation (arrows) to openings and back side of fuel tank partition wall.
^ Install new fuel tank partition wall in reverse order, including reinstallation of spare tire cover and vent hose clips.
Note:
Do not reinstall bolt going through bolt hole (B) at this time (this bolt will be used to secure pressure relief valve bracket).
12. Install new ORVR vent pipe (A, Figure 12).
^ Route formed end of ORVR vent pipe between soft top hydraulic lines (B) and trunk lid support struts (C).
^ Attach felt tape (D) where formed end of ORVR vent pipe contacts soft top hydraulic lines (refer to position of felt tape on original pipe).
13. Install new charcoal canister in reverse order.
Note:
Ensure all hoses are secured to fittings on charcoal canister and vent pipes with hose clamps.
14. Install new vent hose and mounting bracket to pressure relief valve.
^ Install new pressure relief valve mounting bracket to pressure relief valve secure with bolts (arrows, Figure 13).
^ Install new vent hose (A, Figure 14) to new pressure relief valve (B) secure with clamp (arrow).
Note:
Ensure vent hose (A) is positioned on pressure relief valve as shown in Figure 13 to allow for proper routing in next step.
15. Install new pressure relief valve (A, Figure 15) and overflow hose (E, Figure 16):
^ Route vent hose (B, Figure 15) into the lower opening in fuel tank partition wall then out of upper opening in wall and over filler neck (C).
^ Attach vent hose (B) to ORVR vent pipe (D), secure with hose clamp (arrow).
^ Slide pressure relief valve bracket tab (A, Figure 16), into stamped slot (B, Figure 16) in fuel tank partition wall.
^ Bolt the right side pressure relief valve bracket (A, Figure 17) to the body using remaining fuel tank partition wall mounting bolt (this also secures the right-side middle area of the partition wall (B, Figure 17) to the body).
^ Install vent hose (D, Figure 16) to fitting on pressure relief valve and secure with hose clamp (C, Figure 16).
^ Install overflow hose (E, Figure 16) to fitting on pressure relief valve (F, Figure 16), secure with hose clamp (arrow, Figure 16).
16. Install new pressure relief valve cover (A, Figure 18)/secure left side of pressure relief valve:
^ Place new pressure relief valve cover (A) over pressure relief valve.
^ Secure left side of cover along with left side of pressure relief valve with plastic nut (arrow) to fuel tank partition wall.
^ Secure right side of cover with plastic nut (not shown).
17. Affix felt tape (B, Figure 19) to fuel tank partition wall behind hose clamp.
18. Insert ORVR vent pipe (A, Figure 19) into support clips (arrows).
19. Connect vent and overflow hoses:
^ Connect vent hose (A, Figure 20) to fitting on filler neck, secure with hose clamp (B).
^ Connect over flow hose (C) to overflow pipe, secure with hose clamp (D).
20. Install new rear trunk panel (covering fuel tank partition wall) and new wind screen cover in reverse order.
21. Reinstall remaining components (tail lamp covers, side trunk panels, etc.) in reverse order of removal.
Parts Information
In Case of Warranty