Emissions, On Board Refueling Vapor Recovery Valve
Date: July 2001Order No.: P-B-47.31/12
Supersedes:
Group: 47
SUBJECT:
MODELS 210.055/065/070/072/074/082/083, MODEL YEARS 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:
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.
1. Remove activated charcoal canister:
^ Remove right rear wheel arch cover (arrow, Figure 1).
^ Disconnect connector (C, Figure 2) from activated charcoal canister shutoff valve (Y5814).
^ Loosen hose clamp (D) and separate vent hose (F) from vent pipe (82/2).
^ Remove nuts (E) securing shutoff valve bracket to wheel arch.
^ Loosen hose clamps (arrows, Figure 3) disconnect vent hoses (B) from vent lines (A).
^ Remove charcoal canister (77, Figure 2) by lifting up and out.
2. Remove rear hat shelf (WIS: AR68.30-P-4580F).
3. Remove pressure relief valve and vent pipe as an assembly.
^ Remove 2 nuts (arrows, Figure 4) securing pressure relief valve bracket to rear shelf.
^ Separate pressure relief valve bracket (A, Figure 5) from bottom of rear shelf (B).
^ Loosen hose clamp (A, Figure 6), separate vent hose (B) from fuel filler neck fitting (C).
^ Loosen clamp (arrow, Figure 7) and separate overflow hose (A) from overflow pipe (B).
^ Pull vent pipe (C) out from grommet (D) in wheel arch and remove pressure relief valve, overflow pipe and vent pipe as an assembly.
4. Remove nut (B, Figure 8) and pull overflow pipe (82/1) out from grommet and remove.
5. Drill 2 pressure relief valve mounting holes using template attached to this Service Information:
^ Remove fuel shutoff valve wire harness grommet (B, Figure 9) from hole in wheel arch.
^ Remove vent pipe and over flow pipe grommets (arrows).
^ Cut 3 large holes into template (arrows, Figure 10).
^ Align holes (arrows, Figure 10) cut in template (A) with existing holes (for wire harness, vent pipe, overflow pipe) in wheel arch and attach template (A) to wheel arch with tape.
^ Drill two, 6 mm holes into wheel arch as indicated on template (B).
Note:
Seal exposed metal inside mounting holes (drilled in previous step) with zinc paint (local purchase).
6. Secure new pressure relief valve bracket (A, Figure 11) to new pressure relief valve (B) with bolts (arrows).
7. Attach new vent hose (C, Figure 11) to pressure relief valve (B), secure with hose clamp (D).
8. Install new vent hose and shutoff valve to new charcoal canister (before installing charcoal canister on vehicle):
^ Connect vent hose (A, Figure 12) to charcoal canister (B, Figure 12), secure with clamp (arrow).
^ Connect shutoff valve (C, Figure 12) to vent hose (D, Figure 12), secure with hose clamp (E, Figure 12).
9. Partially install pressure relief valve to charcoal canister (before installing charcoal canister on vehicle):
^ Position pressure relief valve assembly (F, Figure 12) behind vent hose (A, Figure 12).
^ Attach shutoff valve holder (A, Figure 13) to mounting tab (arrow, Figure 13) on pressure relief valve bracket.
Note:
Do not attach vent hose (A, Figure 12) to pressure relief valve (F, Figure 12) at this time.
10. Install new charcoal canister assembly (B, Figure 12) to mounting bracket on wheel arch.
11. Secure new pressure relief valve to wheel arch, connect vent hose:
^ Insert two mounting bolts (arrows, Figure 14) into holes drilled in step 5:
^ Mounting bolt specifications:
- Dia=5 mm
- Length=20 mm.
^ Install pressure relief valve assembly (B, Figure 15) to mounting bolts (arrows, Figure 14), secure with two nuts (arrows, Figure 15).
^ Connect vent hose (A, Figure 15) to pressure relief valve (B, Figure 15), secure with hose clamp (C, Figure 15).
12. Connect vent hose (D, Figure 15) to elbow pipe (E), secure with clamp (F)
13. Install grommet (G, Figure 15) into hole in wheel arch, insert elbow pipe (E) into grommet (G).
14. Install new overflow pipe:
^ Connect one end overflow hose (A, Figure 16) to pressure relief valve (B) then connect other end of hose (A) to overflow pipe (C), secure with clamps (arrows).
^ Secure overflow pipe (C) to wheel arch with mounting nut (D)
15. Connect new vent hoses from filler neck to charcoal canister:
^ Connect vent hose (A, Figure 17) to filler neck fitting (B), secure with hose clamp (arrow).
^ Connect vent hose (A, Figure 18) to small elbow pipe (B) secure with hose clamp (arrow).
16. Install new plug (D, Figure 18) into hole in wheel arch.
17. Install wire harness and grommet (C, Figure 18) into hole in wheel arch.
18. Connect wire harness connector (A, Figure 19) to shut-off valve (B).
19. Connect vent hoses (B, Figure 20) to charcoal canister vent lines (A), secure with clamps (arrows).
20. Install remaining components (wheel arch cover, hat shelf, etc.) in reverse order.
Parts Information
In Case of Warranty