2021-2025 Stellantis EVAP System Hard to Fill TSB

Owners of various 2021-2025 Stellantis vehicles may encounter a "Hard to Fill condition" when refueling, indicating a potential problem with the evaporative emission (EVAP) system. This manufacturer communication, TSB 9100471, provides guidance for diagnosing and resolving these fuel system issues, including problems with the Evaporative System Integrity Module (ESIM) Detector and the vapor canister.

Symptoms of a "Hard to Fill condition"

The primary symptom addressed by TSB 9100471 is difficulty filling the fuel tank at the gas station. This often manifests as the fuel pump nozzle repeatedly clicking off, even when the tank is not full, making it challenging to complete refueling.

Diagnosis and Trigger Conditions

Before any parts are replaced, especially the vapor canister, technicians are instructed to replicate the "Hard to Fill condition" at a gas station. If the condition is confirmed, the diagnostic process for the Stellantis EVAP Hard to Fill issue involves several checks:

• Hose Inspection: Examine the Clean Air Hose between the ESIM and the EVAP Air Filter for any kinks or pinches. Also, check the Vapor Hose between the Fuel Tank and the Vapor Canister for similar obstructions.
• Filter Inspection: The EVAP Air Filter should be checked for plugging or restriction.
• Fuel Presence Check: Determine if the Vapor Canister or the Recirculation Line contains fuel. This indicates a potential flooding issue within the EVAP system.
• Internal Vapor Line Connection: If fuel is found in the vapor canister or recirculation line, the fuel tank must be dropped. The FDM Lock Ring is then removed to verify that the internal Vapor Line is properly connected to the Fuel Delivery Module (FDM) Port.

Repair Procedure Summary

If the diagnosis points to an issue with the Evaporative System Integrity Module (ESIM) Detector, and not the vapor canister itself, only the ESIM Detector should be replaced. However, if the "Hard to Fill condition" is replicated and further diagnostics reveal other issues, the following steps are outlined in TSB 9100471:

• If the EVAP Air Filter is restricted, it must be replaced.
• If fuel is discovered within the Vapor Canister or the Recirculation Line, the repair involves dropping the fuel tank. The FDM Lock Ring is then removed to inspect the connection of the internal Vapor Line to the FDM Port. If this line is found to be disconnected, any fuel present in the internal Vapor Line must be drained, and the line properly reconnected to the FDM. Following this, both the Vapor Canister and the ESIM should be replaced.

Required Parts

This TSB may require the replacement of specific components to resolve the Stellantis EVAP Hard to Fill issue. These include the Evaporative System Integrity Module (ESIM) Detector, the EVAP Air Filter, and the Vapor Canister. The manufacturer communication lists various part numbers associated with these components, such as 52029779A$, 52029780A$, 52030368A$, 57009312A$, and others. Technicians should refer to the full bulletin for the complete list of applicable part numbers.

What Owners Should Do

If your 2021-2025 Stellantis vehicle is experiencing a "Hard to Fill condition" or other fuel system issues, it is recommended to schedule an appointment with an authorized dealer. Inform them about the symptoms you are experiencing. The dealer will perform the necessary diagnostic procedures outlined in TSB 9100471 to identify the root cause and apply the appropriate repair.

Source: NHTSA manufacturer communication 11015810.