STAR Case. Release Date: 08/26/2016

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Lawrence French
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1 Case Number: S Release Date: 08/26/2016 Symptom/Vehicle Issue: Fuel Fill System Diagnostic Procedure for PL/KL/UF Vehicles Addressing Fuel Fill Diagnostics/Hard to Fill/Premature Fill Nozzle Shut Off. Discussion: The information that follows is meant to be supplemental to any service information/diagnostic procedures found in TechCONNECT. Please refer to TechCONNECT for additional information. If this information conflicts with what is found in the service/diagnostic information found in TechCONNECT, please contact technical assistance for clarification.

2 Note: The PL/KL/UF Fuel System images below should be used for reference for the diagnostic procedures that follow.

4 Slow Fill or Hard-to-Fill Diagnostic Procedure 1. Verbally confirm customer complaint. Has the vehicle always had this issue or is it recent? Does it occur on all fill-ups or is it intermittent? Is the issue only on high flow and is it okay on low flow of the fill nozzle? 2. Scan and record any fuel-related P-Codes 3. Line Check - Put vehicle up on hoist and visually inspect, by feel or with a mirror, for a dip, kink, bend or twist condition in the fill hose, airline, recirculation line, or canister line. The recirculation line and canister line are connected to the flange mounted Multifunctional Control Valve (MFCV). These lines pass through the frame rail of the vehicle. Check this area for any dips, kinks, bend or twist conditions. Check that the airline is connected to both the Evaporative System Integrity Monitor (ESIM) and the fresh air filter. The rear wheel liner will need to be removed in order to assess the recirculation and canister line routings. Were any problems found? No - Continue to step 4. Yes For a disconnected airline, replace the ESIM and evaporative canister and proceed to step 11 Fuel Tank Fill Check. For a kink, bend or twist, straighten or replace as necessary, document on the repair order and proceed to step 11 Fuel Tank Fill Check. 4. Fresh Air Filter and Filler Cap Check Disconnect the fresh air filter and tap it on a table to determine if the fresh air filter is dirty or plugged. The rear wheel liner will need to be removed in order to assess the fresh air filter. Remove the filler cap and tap it on the table to see if it is dirty. Were any problems found? No - Continue to step 5. Yes Replace fresh air filter. Proceed to step 11 Fuel Tank Fill Check. Yes Replace filler cap. Proceed to step 11 Fuel Tank Fill Check.

5 5. Recirculation line check (at fill pipe) - Remove the recirculation line from the fill pipe and remove the fill hose at the fuel tank connection to the Inlet Check Valve (ICV). The filler cap should still be on. Blow air into the recirculation line and air with no contamination should flow freely out of the fill hose. Were any problems found? No - Continue to step 6. Yes Replace fuel fill pipe and proceed to step 11 Fuel Tank Fill Check. 6. Fuel Tank Inlet Check Valve (ICV) Check The fill hose should already be removed from the ICV. Visually look inside the ICV for an obstruction. If obstructed, remove the object if possible. Using a long thin object (not a screwdriver) that will not damage the seal on the check valve or the anti-siphon features inside the ICV, push the object into the ICV to verify that it is free of obstruction. There is a spring behind the flap, so there will be some resistance, but it should move freely and not stick. Were any problems found? No - Continue to step 7. Yes If an obstruction was found, but the ICV moves freely, proceed to step 11 Fuel Tank Refill Check. If the ICV does not move freely, replace the fuel tank and proceed to step 11 Fuel Tank Fill Check. 7. Reassemble the components removed in the earlier steps. 8. Evaporative Canister weight check Remove the wheel liner and disconnect the lines from the evaporative canister. Disconnect the electrical connector, and then remove the evaporative canister/esim assembly from the vehicle. Use a weight scale such as one for shipping parts or mail to weigh the assembly. The evaporative canister parts numbers based upon platform with their corresponding weights are located below. KL / PF / UF AH AA evaporative canister weight 1,687 grams / 3.72 lbs. KL / PF/ UF AF AA evaporative canister weight 1,557 grams / 3.43 lbs.

6 Were any problems found? Is the evaporative canister above the desired weight? No - Continue to step 9. Yes Look into the ESIM ports to see if the ESIM floats have any appearance of rust or dirt. Is the ESIM seal swollen or is the shape distorted? If the ESIM float is clean, replace the evaporative canister. If the ESIM appears to have rust, dirt or distortion, replace both evaporative canister and ESIM. Proceed to step 11 Fuel Tank Fill Check. 9. Internal Grade Vent Valve Connection Check Please note that this is a very specific customer complaint. The customer should state that they experience engine hesitation after filling the fuel tank. The hard to fill condition will worsen over time as the evaporative canister is subjected to more fuel. Remove the primary side Fuel Delivery Module (FDM) and check to confirm that the 5/16 female SAE quickconnect is properly attached to the 5/16 male SAE quick-connect port on the underside of the FDM flange. Were any problems found? No - Continue to step 10. Yes If the 5/16 female SAE quick-connect is disconnected, reconnect the female-to-male interface. Confirm the connection is properly made with a tug test (pull on the 5/16 female SAE quick-connect and the SAE quick-connect with the vapor line should not fall off). Proceed to step 11 Fuel Tank Fill Check to confirm the issue is eliminated. 10. Nothing found in step 1 through 9, reassemble all components removed in earlier steps and proceed to step Fuel Tank Fill Check with Problem Identified and Repaired Take the vehicle to the gas station and determine if it fills normally. Fuel tank fills normally Problem found and repaired. Still Hard to Fill Return above to the step below where you found an issue and continue diagnostic testing.

7 12. EVAP System Check Disconnect the canister line on the fuel tank flange mount MFCV. Take the vehicle to the gas station and determine if it fills normally. Fuel tank fills normally Replace the canister line, evaporative canister, ESIM assembly and then refuel to verify the problem is repaired. Still Hard to Fill Move to step Recirculation Line Check Reconnect the canister line at the flange mount MFCV and disconnect the recirculation line at the flange mount MFCV. Take the vehicle to the gas station and determine if it fills normally. Fuel tank fills clean Replace the recirculation line, fill pipe and then refuel to verify the problem is repaired. Still Hard to Fill Replace the fuel tank and refuel to verify the problem is repaired.

P0441-EVAP PURGE SYSTEM PERFO... P0441-EVAP PURGE SYSTEM PERFORMANCE

P0441-EVAP PURGE SYSTEM PERFO... P0441-EVAP PURGE SYSTEM PERFORMANCE For a complete wiring diagram, refer to the Wiring Information. Theory of Operation EVAP SYSTEM COMPONENTS CALLOUT DESCRIPTION 1 Filter