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Emissions Control System: Removal & Installation Dodge Nitro I

Emission Applications 13 illustrations ~1281 words

REMOVAL - 3.7L

The PCV valve is located at the rear of the left cylinder head.

Scheme 7

Scheme 7
Scheme 7
  1. Remove line (1) and rubber connector hose from PCV valve.
  2. Unthread PCV valve (3) from metal fitting (2).

INSTALLATION - 3.7L

  1. Check condition of PCV valve rubber O-ring (2).
  2. Clean fitting (2).
  3. Install PCV valve (3) into fitting (2).
  4. Install PCV line (1) and rubber connector to valve.

Scheme 8

Scheme 8: REMOVAL - 4.0L
Scheme 8: REMOVAL - 4.0L

The PCV valve (2) is located at the rear of the right valve cover (3).

  1. Remove hose clamp and rubber hose (1) from PCV valve.
  2. Unthread PCV valve (2) from rear of valve cover (3).

INSTALLATION - 4.0L

  1. Check condition of PCV valve rubber O-ring.
  2. Clean PCV fitting.
  3. Thread and tighten PCV valve (2) into rear of valve cover (3).
  4. Install rubber PCV hose (1) and hose clamp to PCV valve.

REMOVAL

The ESIM (EVAP System Integrity Monitor) switch is attached to the EVAP canister and is usually not serviceable. Replace the switch by replacing the EVAP canister. Refer to EVAP canister REMOVAL / INSTALLATION .

If servicing separately, refer to the following

Scheme 9

Scheme 9: REMOVAL
Scheme 9: REMOVAL
1 - EVAP Canister
2 - ESIM Switch
3 - Electrical Connector

The ESIM switch (2) is located on the EVAP canister (1) The picture displays a typical EVAP Canister and a typical ESIM switch.

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
  1. Remove both plastic lines from switch by folding line tabs (2).
  2. Disconnect electrical connector at switch.
  3. Clean any dirt from ESIM switch and its lines.
  4. A lock tab (see arrow in illustration) is used on the back of the switch. Push lock tab towards switch while rotating switch counterclockwise 1/4 turn for removal.
  5. The fresh air lines and hoses from the ESIM must have a clear opening to the atmosphere. Check the fresh air lines, including the fresh air filter, for obstructions or restrictions at the ESIM. Also check the routing to the exit to atmosphere. If a restriction is present, the system will not allow free flow passage of clean air, and an early shut off of the fuel fill nozzle may occur during fuel fill.

INSTALLATION

The following pictures display a TYPICAL EVAP Canister and a typical ESIM switch. After installing any ESIM switch, the electrical connector on the switch must be in the 3 O'clock position. This step must be done for proper ESIM switch operation.

  1. The fresh air lines and hoses from the ESIM must have a clear opening to the atmosphere. Check the fresh air lines, including the fresh air filter, for obstructions or restrictions at the ESIM. Also check the routing to the exit to atmosphere. If a restriction is present, the system will not allow free flow passage of clean air, and an early shut off of the fuel fill nozzle may occur during fuel fill.
  2. Be sure O-ring (2) and EVAP canister opening are clean. 1 - EVAP Canister 2 - ESIM Switch 3 - Electrical Connector CAUTION: The electrical connector (3) on the ESIM switch must be in 3 O'clock position after installation. This step must be done for proper switch operation.
  3. Position ESIM switch (2) into EVAP canister (1) and rotate until electrical connector is in 3 O'clock position (3).
  4. Connect electrical connector.
  5. Connect plastic lines to ESIM switch.
  1. Position canister locating pins (1) into bracket (2).
  2. Install nut/bolt (1) at front of canister mounting bracket (2).
  3. Clean dirt or debris from canister vacuum lines.
  4. Connect electrical connector (3) to ESIM switch (2).
  5. Connect rubber hose (6) to ESIM switch (2).
  6. Connect quick-connect fitting (5) to EVAP canister.
  7. Lower vehicle.

Scheme 13

Scheme 13: REMOVAL
Scheme 13: REMOVAL

The crankcase heater (2) is located in the hose (1) leading to the crankcase breather (6).

  1. Disconnect electrical connector (5).
  2. Separate hose (1) from heater.
  3. Separate heater from hose (3).

The crankcase heater (2) is located in the hose (1) leading to the crankcase breather (6).

  1. Twist heater (2) into hose (3).
  2. Twist hose (1) into heater.
  3. Connect electrical connector (5).

Scheme 14

Scheme 14: VALVE - EGR - 3.7L
Scheme 14: VALVE - EGR - 3.7L

The electronic EGR valve and solenoid assembly (1) is attached to the rear of the left cylinder head.

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16
  1. Use a diagnostic scan tool to record any DTC's (Diagnostic Trouble Codes).
  2. Disconnect and isolate the negative battery cable. An exhaust gas routing tube (1) connects the EGR valve (4) to the intake manifold.
  3. Remove two tube mounting bolts (2).
  4. Remove tube (1) from solenoid (4). Slip opposite end of tube (6) from intake manifold.
  5. Remove gasket (3) located between EGR valve solenoid and tube flange.
  6. Disconnect electrical connector (3) at solenoid (1).
  7. Remove two EGR valve solenoid mounting bolts (2).
  8. Remove solenoid (1) from engine.
  9. Remove and discard gasket (1) located under EGR solenoid.
  1. Install new gasket between EGR solenoid/valve (2) and rear of cylinder head.
  2. Position EGR solenoid/valve assembly to rear of cylinder head. Install and tighten two mounting bolts (6).
  3. Install new O-ring to intake manifold end of tube (5).
  4. Install two flange mounting bolts (3) at intake manifold. Do not tighten bolts at this time.
  5. Install new gasket (5) between EGR valve solenoid and tube flange.
  6. Position tube (4) to solenoid (2). Slip opposite end of tube (4) into intake manifold.
  7. Install and tighten two flange bolts (3) at solenoid.
  8. Connect electrical connector (6) to solenoid (1).
  9. Tighten flange bolts (3).
  10. Connect negative battery cable.
  11. Using a diagnostic scan tool, erase any previously recorded DTC's (Diagnostic Trouble Codes).

The EGR valve (5) is located at the rear of the intake manifold (7).

  1. Clean mounting areas at bottom of EGR valve and at top of intake manifold.
  2. Place new mounting gasket between EGR valve and intake manifold.
  3. Install EGR valve (5) and mounting bolts (8) to intake manifold. Tighten bolts to 15 N.m (11 ft. lbs.) torque.
  4. Connect vacuum line to fitting (6).
  5. Install EGR cooler (8). Refer to «COOLING»(ref-306154) article for removal procedures .
  6. Install plastic engine cover.
  7. Connect and negative battery cable to battery.

Scheme 17

Scheme 17: REMOVAL
Scheme 17: REMOVAL

The EGR Solenoid (3) is located on the top of valve cover.

  1. Remove plastic engine cover.
  2. Disconnect electrical connector (2).
  3. Disconnect vacuum/pressure lines (1).
  4. Remove two mounting bolts (4) and remove solenoid.

The EGR Solenoid (3) is located on the top of valve cover.

  1. Position solenoid (3) to valve cover and install two mounting bolts (4).
  2. Connect electrical connector (2).
  3. Connect vacuum/pressure lines (1).
  4. Install plastic engine cover.

The EGR air control valve (9) is located near the center of the intake manifold (7). A cast intake housing (3) connects the control valve to the intake manifold.

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19
  1. Disconnect and isolate negative battery cable at battery.
  2. Remove plastic engine cover.
  3. Remove rubber intake tube clamp (3).
  4. Disconnect rubber tube (2) from air control valve (1).
  5. Disconnect air control valve electrical connector from control valve at point (2).
  6. Remove EGR air control valve mounting bolts (2) and remove valve (9).
  7. Remove and discard old mounting gasket located between EGR air control valve (9) and intake manifold connecting housing (3).
  8. Clean mounting areas at bottom of air control valve and at intake manifold connecting housing (3).

The EGR air control valve (9) is located near the center of the intake manifold (7). A cast intake housing (3) connects the control valve to the intake manifold.

  1. Clean mounting areas at bottom of air control valve and at intake manifold connecting housing (3).
  2. Install new mounting gasket between EGR air control valve (9) and intake manifold connecting housing (3).
  3. Install EGR air control valve and mounting bolts (2). Tighten bolts to 13 N.m (10 ft. lbs.) torque.
  4. Connect air control valve electrical connector to control valve at point (2).
  5. Connect rubber tube (2) to air control valve (1).
  6. Install and tighten rubber intake tube clamp (3).
  7. Install plastic engine cover.
  8. Connect negative battery cable to battery.

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