B. Installation of Pressure Relief Valve/ORVR Components

1. Installation of new ORVR vent pipe (A, Figure 12):

Position vent pipe (A, Figure 12) as shown, then route behind speaker (B) in direction of arrow.





^ Insert bottom of vent pipe into grommet (arrow, Figure 13).

^ Attach rubber insulation around pipe, where it comes in close proximity to back of fuel tank mounting bracket (E).

^ Secure vent pipe (A) to body with nut (D).

^ Reinstall vent hose (B [removed in step 7 of subject A]) to vent pipe (A), secure with hose clamp (C).





2. Extend the length of activated charcoal canister shutoff valve harness (A, Figure 14).

DANGER!
Use of heat gun is required to properly melt solder inside of wire connector. Please ensure the following precautions are taken:

^ Area where heat gun is used is well ventilated

^ Previously removed ORVR components, fuel tank and fuel drainage containers are not in the immediate area.

^ All open fuel/vent lines and ORVR components are either plugged or pinched off.

^ Cut harness (approx.) 6" from connector (B).

^ Splice 2 new wires into original harness using wire connectors (refer to WIS AR00.19-P-0100-09A).

- Wire length: 6"

- Wire cross section: .75 sq.mm.

^ Cover new section of wire harness (A) with plastic sheathing (local purchase), cover wire connections (arrows) and areas of harness not covered with sheathing, with premium quality electrical tape (e.g., 3M scotch 33).

3. Reinstall fuel tank in reverse order (WIS; AR47.10-P-4100GA).





Note:
Do not reconnect return hose (D, Figure 16) to fuel tank fitting, this hose will be replaced in step 5).





4. Install body plug (arrow, Figure 15) into opening in underbody where of previous version ORVR vent pipe fitting was protruding.

5. Replace fuel return hose (D, Figure 16):

WARNING!
Fuel may be present in return line (D). Remove plug or pinch clamp (previously installed) from hose (D) and drain any fuel which may be present in return line, into proper container.

Loosen hose clamp (C), disconnect hose (D) from return line (E), remove hose (D).





^ Install fuel new return hose (B, Figure 17):

Connect one end of return hose (B) to return line (D) and other end to fuel tank fitting (C), secure with hose clamps (arrows).

6. Connect vent hose (C, Figure 18) to fuel tank fitting, secure with hose clamp (D).

Note:
Charcoal canister shown in Figure 18 will be installed in next step.





7. Install new activated charcoal canister (C, Figure 19):

^ Install new vent hoses (A and B, Figure 19) to fittings on charcoal canister (C), secure with hose clamps (arrows).

^ Install charcoal canister to bracket on vehicle.

^ Connect vent hose (A, Figure 18) to vent line (B, Figure 18), secure with hose clamp (arrow, Figure 18).





^ Route shut-off valve harness (A, Figure 20) along back side of charcoal canister, away from hose clamps.

^ Connect harness connector (B) to shut-off valve (C [integrated into activated charcoal canister]), secure with wire tie (arrow).





^ Connect new fuel tank vent hose (A, Figure 21) to charcoal canister fitting, secure with hose clamp (arrow).

8. Connect new ORVR vent hose (B, Figure 21) to ORVR vent pipe, secure with hose clamp (C).





9. Install new pressure relief valve (A, Figure 22):

^ Install pressure relief valve (A, Figure 22) to pressure relief valve bracket (B), secure with bolts (arrows).

^ Install hose clip (C) to bracket (B).





^ Connect vent hose (B, Figure 23) to pressure relief valve fitting (D), secure with hose clamp (C).

^ Secure pressure relief valve bracket (A) to charcoal canister (E) with two bolts (arrows).





^ Connect ORVR vent hose (A, Figure 24) and overflow hose (B) to pressure relief valve (C), secure with hose clamps (arrows).

^ Secure overflow hose (B) to body with mounting clip (D).





^ Secure fuel return hose (B, Figure 25) to mounting clip (A).

10. Reinstall remaining components (trunk panels, CD changer, fuel pump cover etc.) in reverse order.