Emissions Control System: Removal & Installation Dodge Avenger II

INSTALLATION

1. Install air pump (3) to bracket (4).
2. Install air pump mounting nuts (5) to bracket (4). Tighten the nuts to 8 N.m (71 in. lbs.).
3. Connect electrical harness connector (1) to the air pump electrical connector (2).
4. Install heat shield (3) and bolt (1) to air pump bracket (2). Tighten the bolt to 8 N.m (71 in. lbs.).
5. Install relay, heat shield (2) and bolt (1) to air pump bracket (3). Tighten the bolt to 8 N.m (71 in. lbs.). NOTE: The quick connect fitting on the air inlet tube is slotted to fit the air pump housing fitting. Line the slot up when making the connection.
6. Install air inlet tube (3) to air pump housing connection (2). A click noise will indicate a good connection.
7. Connect the negative battery cable, tighten the nut to 5 N.m (45 in. lbs.).

Scheme 24

1. Disconnect air flow sensor electrical connector (4).
2. Remove constant tension clamps (1), (2) securing the air flow sensor (3).
3. Remove air flow sensor (3) from hoses.

1. Note the arrow direction on the sensor and correctly position the air flow sensor (3) to hoses.
2. Install constant tension clamps (1), (2) to secure air flow sensor (3) to hoses.
3. Connect air flow sensor electrical connector (4).

Note. The quick connect fitting on the air inlet tube is slotted to fit the air pump housing fitting. Line the slot up when making the connection.

1. Install air inlet tube (3) to air pump housing connection (2). A click noise will indicate a good connection.
2. Install mass air flow (MAF) sensor (1) and constant tension clamp (2) to air inlet tube (4).
3. Position MAF sensor wiring to air inlet tube (4). Install new tie straps (3) securing the MAF sensor wiring to air inlet tube (4).

Scheme 25

The air injection check valve (1) is a one-valve check valve that allows air to flow in one direction only. The valve is located at exhaust side of the engine at the top of the exhaust manifold.

REMOVAL

1. Remove air outlet tube (3) by pushing the ends (2) together, while pulling the air pump outlet tube (3) away from air injection check valve (1).
2. Remove air injection check valve mounting bolts (4).
3. Remove air injection check valve (1) and gasket (5) from pipe. Clean old gasket material from air injection pipe.

Note. Make sure the old gasket material is completely removed from air injection pipe.

1. Install new gasket (5) and air injection check valve (1) to pipe.
2. Install air injection check valve mounting bolts (4). NOTE: The quick connect fitting on the air outlet tube is slotted to fit the air injection check valve fitting. Line the slot up when making the connection.
3. Install air pump outlet tube (3) to air injection check valve (1) connection. A click noise will indicate a good connection.

Scheme 26

The plastic fuel tank filler tube cap is threaded onto the end of the fuel fill tube. Models are equipped with a 1/4 turn non-locking cap.

1. Install EVAP canister (1) mounting bolts and tighten.
2. Connect filter hose to canister (2).
3. Connect electrical connector (1)
4. Connect hoses (2).
5. Lower vehicle.
6. Connect negative battery cable.

1. Install evaporator purge solenoid (1) to bracket. Make sure the tab (2) secures the solenoid (1) to the bracket.
2. Install quick connect fuel tank hose (3) to evaporator purge solenoid (1).
3. Install purge hose (4) to evaporator purge solenoid (1).
4. Connect electrical connector (5) to evaporator purge solenoid (1).
5. Install the PCM. Refer to «INSTALLATION»(ref-305775-S11797225582008120200000) .
6. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).

Scheme 27

The ESIM (Evaporative System Integrity Monitor) is very similar to the NVLD. However, the design of the ESIM has been simplified and unlike the NVLD the ESIM does not require a solenoid. The ESIM mounts directly to the canister, eliminating the need for a mounting bracket. It is critical that the ESIM is mounted vertically. On vehicles where the canister is mounted on an angle, the ESIM requires an adapter to maintain a vertical position. When the ESIM is installed vertically, the electrical connector is in the 3 o'clock position.

Scheme 28

The ESIM assembly consists of a housing, a small weight and a large weight that serve as check valves, a diaphragm, a switch and a cover. There is one large weight and one small weight check valve in the ESIM assembly. A seal is attached at the end of each weighted check valve. The large weight check valve seals for pressure. The small weight check valve seals for vacuum. The weighted check valves are contained within the ESIM housing.

Scheme 29

The ESIM (Evaporative System Integrity Monitor), while physically different than the NVLD system, performs the same basic function as the NVLD does - controlling evaporative emissions. The ESIM has been simplified because the solenoid used on the NVLD is not used on the ESIM.

The ESIM consists of housing, two check valves (sometimes referred to as weights), a diaphragm, a switch and a cover. The larger check valve seals for pressure and the smaller one seals for vacuum.

During refueling, pressure is built up in the evaporative system. When pressure reaches approximately.5 inches of water, the large check valve unseats and pressure vents to the fresh air filter.

Conversely, when the system cools and the resulting vacuum lifts the small check valve from its seat and allows fresh air to enter the system and relieve the vacuum condition. When a calibrated amount of vacuum is achieved in the evaporative system, the diaphragm is pulled inward, pushing on the spring and closing the contacts.

The ESIM conducts test on the evaporative system as follows: An engine off, non-intrusive test for small leaks and an engine running, intrusive test for medium/large leaks.

The ESIM weights seal the EVAP. system during engine off conditions. If the EVAP. system is sealed, it will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. When the vacuum in the system exceeds about 1" H20, the vacuum switch closes. The switch closure sends a signal to the GPEC1. In order to pass the non-intrusive small leak test, the ESIM switch must close within a calculated amount of time and within a specified amount of key-off events.

If the ESIM switch does not close as specified, the test is considered inconclusive and the intrusive engine running test will be run during the next key-on cycle. This intrusive test will run on the next cold engine running condition.

Conditions for running the intrusive test are

1. After the vehicle is started, the engine coolant temperature must be within 10°C (50°F) of ambient to indicate a cold start.
2. The fuel level must be between 12% and 88%.
3. The engine must be in closed loop.
4. Manifold vacuum must be greater than a minimum specified value.
5. Ambient temperature must be between 4°C and 37°C (39°F and 98°F) and the elevation level must be below 8500 feet.

The test is accomplished by the GPEC1 activating the purge solenoid to create a vacuum in the evaporative system. The GPEC1 then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the switch does not close, then a general evaporative failure is recorded. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test.

Even when all of the thresholds are met, a small leak won't be recorded until after the medium/large leak monitor has been run. This is accomplished by the GPEC1 activating the purge solenoid to create a vacuum in the evaporative system. The GPEC1 then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the medium/large leak test runs and the ESIM switch doesn't close, a general evaporative test is run. The purge solenoid is activated for approximately 10 seconds, increasing the amount of vacuum in the system. IF the ESIM switch closes after the extended purge activation, a large leak fault is generated. If the switch doesn't close, a general evaporative system fault is generated.

The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test.

Stage one of the purge monitor is non-intrusive. GPEC1 monitors the purge vapor ratio. If the ratio is above a calibrated specification, the monitor passes. Stage two is an intrusive test and it runs only if stage one fails. During the stage two test, the GPEC commands the purge solenoid to flow at a specified rate to force the purge vapor ratio to update. The vapor ratio is compared to a calibrated specification and if it is less than specified, a one-trip failure is recorded.

The ESIM switch stuck closed monitor checks to see if the switch is stuck closed. This is a power down test that runs at key-off; when the GPEC1 sees 0 RPM, the purge solenoid is energized for a maximum of 30 seconds, venting any vacuum trapped in the evaporative system. If the switch opens or was open before the test began, the monitor passes. If the switch doesn't open, the monitor fails. This is a two-trip MIL. The star scan tool can be used to force the ESIM switch stick closed monitor to run.

The GPEC1 also uses the ESIM to detect a loose or missing gas cap. The GPEC1 controller looks for a change in the fuel level (25% minimum) and then gas cap is loose or missing. If a medium/large leak is detected, a loose gas cap light illuminates and a pending one-trip fault code is set. On the GPEC1, this is a three-trip fault before the code matures

1. Position and install solenoid valve block onto bracket. 1 - Item_1 2 - Item _2
2. Connect vacuum harness (2) to solenoid valve block.
3. Connect solenoid valve block electrical connector (1).
4. Connect negative battery cable.
5. Install air cleaner housing. Refer to «INSTALLATION»(ref-305761-S35199583532008120200000) . Refer to «INSTALLATION»(ref-305762-S39775229262008120200000) . Refer to «INSTALLATION»(ref-305763-S10239893242008120200000) .
6. Install air inlet duct.