Some drivers have been leading their vehicles to the gas pump, but can’t seem to make the thirsty cars drink. Several 2004-2009 Chrysler^® Group models are known to be hard to fill with fuel. Sometimes the fuel nozzle shuts off repeatedly. This problem may have a number of different causes, the fuel tank being least likely. There’s no need to waste time exploring the issue, when a path to a solution may already be at hand. This technical service bulletin issued by Chrysler offers a diagnostic procedure to help quickly diagnose and repair the condition.

Difficult Fuel Fill

Affected Vehicles
Various 2004 – 2009 Chrysler, Dodge^®, Ram^® and Jeep^® models

NOTE: This bulletin applies to all vehicles equipped with a gasoline engine.

Review safety procedures in ALLDATA Repair^® before beginning.

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 halves 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 Step # 14.
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 following OEM procedures.

NOTE: This Repair/Service Procedure is intended for use by trained, professional technicians with the knowledge, tools and equipment to do the job properly and safely. It is recommended that this procedure not be performed by “do-it-yourselfers.”