Charcoal Canister

Remove and replace the EVAP charcoal canister located in the right rear wheel well area, including disconnecting vapor lines and mounting hardware.

Warnings

Tools required

Parts

• Charcoal canister assembly × 1 — Use OEM specification
• Vapor line quick-connect clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and apply parking brake.
2. Place wheel chocks in front of front wheels.
3. Loosen right rear wheel lug nuts while vehicle is on the ground.
4. Raise right rear corner of vehicle with jack and support securely on jack stand placed under frame rail.
5. Remove right rear wheel completely.

Procedure

1. 1

   Locate charcoal canister
   From beneath the right rear wheel well, locate the charcoal canister mounted vertically to the inner body structure forward of the rear suspension. The canister is a black cylindrical component approximately 8 inches tall with vapor lines connected to the top.
2. 2

   Disconnect vapor lines from canister
   Identify the vapor line connections at the top of the canister. Identify the vapor line connections at the canister. Verify the connection type against factory documentation, as the 1992 Viper may use either quick-connect fittings or clamped/push-on rubber hoses. If quick-connects are present, press the release tabs and pull the lines straight off; if clamped hoses are used, loosen the clamps and work the hoses off the nipples. Note the number and routing of each vapor line before disconnecting. If the clips are corroded or difficult to release, use a small flathead screwdriver to depress the locking tab while pulling the line.
   ⚠Do not force or twist the vapor lines. Quick-connect fittings release straight off when tabs are properly depressed.
3. 3

   Remove canister mounting hardware
   Locate the mounting bracket securing the canister to the body. Remove the mounting bracket bolts (verify exact count against factory documentation) securing the canister bracket to the body structure using a socket and ratchet. Support the canister with one hand while removing the final fastener to prevent it from falling.
4. 4

   Remove canister from vehicle
   Once mounting bolts are removed, carefully maneuver the canister downward and out through the wheel well opening. The canister may need to be angled slightly to clear the suspension components during removal.
5. 5

   Inspect vapor lines and fittings
   Inspect all vapor line quick-connect fittings for damage, cracks, or excessive wear. Check the vapor lines themselves for cracks, brittleness, or deterioration. Replace any damaged components. Verify that the quick-connect clips are intact and functional.
6. 6

   Install new charcoal canister
   Position the new charcoal canister in the mounting location, angling it through the wheel well as needed to clear suspension components. Align the mounting bracket with the body mounting holes. Install the 2 mounting bolts finger-tight initially to allow for final positioning adjustment.
7. 7

   Reconnect vapor lines
   Push each vapor line straight onto its corresponding canister nipple until you hear or feel a distinct click, indicating the quick-connect fitting has locked. Gently tug on each line to verify it is securely connected and will not pull off. Ensure each line is routed without kinks or sharp bends.
8. 8

   Torque mounting hardware
   Using a torque wrench, tighten the canister mounting bracket bolts to the factory-specified torque (typically approximately 7-17 ft-lbs for small bracket fasteners; verify exact spec and bolt count for the 1992 Viper). Verify the canister is secure and does not move when pulled by hand.
9. 9

   Reinstall wheel
   Reinstall the right rear wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to the factory-specified value (verify exact spec for the 1992 Viper) in a star pattern. Fully lower the vehicle and remove jack stands and jack.

Reassembly

1. Ensure all vapor line quick-connect fittings are fully seated and locked.
2. Verify the canister mounting bolts are torqued to specification and the canister does not move.
3. Double-check wheel lug nuts are properly torqued after lowering vehicle.

Verification

• Start the engine and allow it to idle for 2-3 minutes. Listen for any hissing sounds from the wheel well area that would indicate a vapor leak.
• With engine running, visually inspect the canister and vapor line connections from beneath the vehicle for any signs of fuel vapor escaping.
• Check that no check engine light or EVAP system codes are present. If codes were present before the repair, they may need to be cleared and the vehicle driven through a complete drive cycle to verify the repair.
• Perform a final inspection to ensure no tools or parts were left in the wheel well area.

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