Constant shut off When fueling

Tiny
METALDAVE
  • MEMBER
  • 2005 DODGE RAM
  • 5.7L
  • V8
  • 4WD
  • AUTOMATIC
  • 201,000 MILES
Hi, all.

I just picked up the truck listed above 2500 XLT 5.7 Hemi, used, and I am unable to fuel the truck. The pump will run for a second and stop, and this is constant.

I'm familiar with TSB 14-001-09 REV. A, and I am stuck at Step 11 in the troubleshooting. This reads:

"Disconnect the control valve to EVAP canister tube at the fuel tank".

I have both the Evaporative Emissions and Fuel System service manuals for the 2005, and I cannot identify or locate the tube they're referring to as "the control valve to EVAP canister tube." Can anyone help point me in the right direction?

Thank you in advance,

- Dave
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Wednesday, June 2nd, 2021 AT 5:10 AM

9 Replies

Tiny
KASEKENNY
  • CERTIFIED MECHANIC
This is talking about the line that runs from the fuel tank to the canister. This TSB contains vehicles that have either an NVLD or ESIM so it just uses the term control valve so they don't have to name each on every line.

Basically follow the line from the tank to the canister and that is the line that you need to disconnect where it asks. More than likely you are going to need a tank. That was a pretty common failure on these vehicles.

Please let us know if you have other questions on this.
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Wednesday, June 2nd, 2021 AT 8:51 AM
Tiny
METALDAVE
  • MEMBER
Thank you very much for the reply; I greatly appreciate the help.

I have traced the hose back from the canister, and it seems to connect to a cylindrical item next to the fuel pump. I’m not sure what this part is called, but I’ve seen a number of variations of this component depending upon the size of the tank with a given Ram model. Can you identify this item?

I’ve included a photo of this item below. There are three hoses connected. Two go to valves at either end of the tank and one of the hoses appears to be the line connecting to the canister. I’m guessing this mystery item is not serviceable (as you implied with the possibility of replacing the tank on the whole).

Ultimately, it would be great to confirm this is the point where I need to disconnect the hose to continue with the TSB troubleshooting procedure. If that cures the problem, I’m probably replacing the tank. If not, I’m hoping it’s the old canister (cheaper and easy to replace).

Thanks again!

- Dave
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Wednesday, June 2nd, 2021 AT 7:12 PM
Tiny
METALDAVE
  • MEMBER
As luck would have it, I was able to find the answer to my recent question in another post:

https://www.2carpros.com/questions/2003-dodge-ram-fuel-pressure

It looks like the "mystery item" is a Liquid Expansion Chamber (per the diagram cited in that post and attached below). I've looked through Chapter 14 (Fuel System) of the service manual, and I don't have that Fuel Delivery Components diagram. It's unfortunate as this diagram matches my Ram 2500's configuration exactly.

Unfortunately, my service manual also doesn't mention this Liquid Expansion Chamber. I've also looked in Chapter 25 (Emissions Control), and that comes up short as well. If anyone is familiar with this diagram and can tell me where it came from, I'd love to get that documentation.

This diagram shows the EVAP Line Connection as well, so now I know where to disconnect and continue working through the TSB. Again, I really wish the TSB had this diagram as well, but better lucky than lost. I will take that next step and report back my findings.

Thanks again for the assistance!

- Dave
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Thursday, June 3rd, 2021 AT 10:00 AM
Tiny
METALDAVE
  • MEMBER
A quick follow-up: I disconnected the EVAP tube at the fuel tank side, and I attempted to fuel up. The issue persisted and the pump clicked off quickly after start. Per the TSB, this would indicate a Fuel Tank Replacement is required. Needless to say, I'm disappointed about this, and I would appreciate if anyone had any suggestions for further diagnosis or repair.

Otherwise, I have to source a fuel tank and, as I understand, these have been discontinued by Mopar. Does anyone have a suggestion on where to look? Pick-a-part?

Thanks again.
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Thursday, June 3rd, 2021 AT 2:10 PM
Tiny
KASEKENNY
  • CERTIFIED MECHANIC
You are correct. Sorry for the delay. I attached the info on this part. It is not called out in the manual for your vehicle but it is the expansion tank/valve/chamber.

Basically it is what controls the vapor from the tank. Either it goes to the canister or a vent if needed. It is not serviced separate so if you disconnected the line from the canister to it and it still did not fill the tank then it does look like you need a tank.

I have heard of people getting them from Legacy part companies that buy the old stock from Mopar and dealers. However, once they are sold out then salvage yards are the only option if no other supplier started making them.

However, the good thing is, this is not a rare truck so I am sure you will find one in good condition.
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Thursday, June 3rd, 2021 AT 7:30 PM
Tiny
METALDAVE
  • MEMBER
Thank you again for all of your insight. That saves me a lot of second-guessing.

I didn’t see an attachment on the last post. I’m guessing you meant to add information on the Liquid Expansion Chamber, so please share for future reference.

I will reach out to my local salvage yards in the morning. The West (where I’m located) also helps when looking for parts in good condition.

Again, I really appreciate the assistance. Thank you very much!

- Dave
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Thursday, June 3rd, 2021 AT 8:21 PM
Tiny
KASEKENNY
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I am sorry. I do not know why it did not attach. I put it below but I suspect you have seen this picture before. The point was, it shows it in the picture but they don't put a call out on it for this engine.

I added it below again. Thanks
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Saturday, June 5th, 2021 AT 8:00 AM
Tiny
METALDAVE
  • MEMBER
Apparently, my fuel filler hose had warped on the inside (without any visible signs on the outside). Per recommendation, I pulled the hose out completely and inspected. I have attached photos of both ends for your reference, and you can see the blockages immediately inside.

My guess is that a combination of heat and rot caused the interior layer of the hose to expand and create bubbles throughout the length of the hose. With that type of blockage, the fuel pump would, naturally, sense resistance and shut down.

It was a challenge to find a replacement part. I confirmed with my local Dodge parts department the OEM replacement part had been discontinued. Looking to aftermarket parts, we found a Spectra FNH219 part that fit the 2005 Ram 2500, and using this part number allowed me to find an equivalent. I was able to order this through O'reilly Auto Parts' online site for delivery to the store. (Notably, the counter could not order the item, but the website worked.)

I was saved a time-consuming and, likely, costly repair by doing a simple diagnostic the Technical Service Bulletin could have, totally, recommended. Once again, common sense prevailed, but, honestly, I hadn't thought of it throughout this troubleshooting process. That's why you need a second set of eyes on the project.

Thank you again for the assistance, and I hope this is a help for future visitors.
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Thursday, June 10th, 2021 AT 4:04 PM
Tiny
KASEKENNY
  • CERTIFIED MECHANIC
That sure will help others. Unfortunately overlooking the obvious happens all too often.

Thanks for the update and I am glad you don't need a tank.
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Thursday, June 10th, 2021 AT 7:43 PM

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