Major Leak. Permanent Fault

Major leak. Permanent fault

Identification
First read Identifying cars constructed according to ORVR Application and ID.

Is the car constructed according to ORVR?

Yes - Safety

No - Major leak. Permanent fault

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Major leak. Permanent fault

Checking cables and terminals
- Check that the fuel tank filler cap is on properly and that its seal is intact.
- Check EVAP canister, roll-over valve, fuel pressure regulator and fuel tank hoses and hose connectors.

Were any faults detected?

Yes -
Remedy faults. Then continue with.

No -

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Remedy the fault
- Remedy the fault

Continue -

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Checking vacuum downstream of the canister purge (CP) valve

- Start the engine and let it idle.
- Disconnect the hose between the canister purge (CP) valve and EVAP canister from the canister purge (CP) valve.

- Disconnect the Volvo Scan Tool (ST) from the VIDA station and use the instrument in stand-alone mode.
- Go into scrolling values list, read off canister purge (CP) valve value. This will show whether the valve is active or not.
- Check that there is vacuum in the canister purge (CP) valve when the valve is activated.

Is there a vacuum?

Yes -

No -

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Checking vacuum to canister purge (CP) valve

- Connect the hose between the canister purge (CP) valve and EVAP canister to the canister purge (CP) valve.
- Start the engine and let it idle.
- Disconnect hose between canister purge (CP) valve and intake manifold from the canister purge (CP) valve.
Check that there is a vacuum in the hose.

Is there a vacuum?

Yes -
Try a new canister purge (CP) valve. Then continue with.

No -
Check if the hose between the canister purge (CP) valve and intake manifold is blocked. Check the hose connection to the intake manifold. Then continue with.

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Replacing component
- Try a new canister purge (CP) valve.

Continue -

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Checking hose
- Check if the hose between the canister purge (CP) valve and intake manifold is blocked. Check the hose connection to the intake manifold.

Select "Continue" when the check has been made.

Continue -

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Checking vacuum at EVAP canister

- Ignition on.
- Remove left fender liner according to
- Remove EVAP canister.

- Connect hose between canister purge (CP) valve and EVAP canister.
- Disconnect the Volvo Scan Tool (ST) from the VIDA station and use the instrument in stand-alone mode.
- Go into scrolling values list, read off canister purge (CP) valve value. This will show whether the valve is active or not.
- Read off the canister purge (CP) valve value to determine whether the valve is activated or not.
- Check that there is vacuum in the hose when the canister purge (CP) valve is activated.

Is there a vacuum?

Yes -

No -
Check if the hose between the canister purge (CP) valve and EVAP canister is blocked or trapped. Then continue with.

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Checking hose
- Check if the hose between the canister purge (CP) valve and EVAP canister is blocked or trapped.

Select "Continue" when the check has been made.

Continue -

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Checking EVAP canister
- Check that all EVAP canister inlets and outlets are airtight.

Are all inlets and outlets are OK?

OK -

Not OK -
Remedy or replace EVAP canister. Then continue with.

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Replacing component
- Remedy or try a new EVAP canister shut-off valve.

Continue -

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Checking hose to fuel tank
- Carefully disconnect the hose to the fuel tank from the EVAP canister.
- Connect a vacuum pump to the hose to the fuel tank.
- Try to pump up a vacuum.

It should not be possible to pump up a vacuum.

OK -

Not OK -
Check that the roll-over valve is airtight. Check that the hose between fuel tank and EVAP canister is airtight and is not trapped. Then continue with.

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Checking roll-over valve
- Check that the roll-over valve is airtight.
- Check that the hose between the fuel tank and EVAP canister is airtight and is not trapped.

Select "Continue" when the check has been made.

Continue -

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Test pressurization of the fuel tank system

- Max 50 liters of fuel in the fuel tank.
- Ignition off.
- Clamp hose between canister purge (CP) valve and intake manifold with a hose clip to seal it off.
- Connect hose from fuel tank to EVAP canister.
- Carefully disconnect the EVAP canister shut-off valve hose from the EVAP canister.
- Connect tool 999 5646 Pressure gauge 999 5646 Pressure Gauge to EVAP canister.
- Set a pressure of 7 kPa. Regulate the pressure with tool 999 5646 Pressure gauge 999 5646 Pressure Gauge.

Warning! Max 10 kPa.

- Let the pressure build up for 5 minutes.
- Shut off the cock (the pressure may drop 1-2 kPa before stabilizing) and read off pressure.
- Wait for 10 minutes.

Warning! Never leave the car unattended with its fuel tank system pressurized.

The pressure should be stable (it may rise a little due to fuel evaporation).

OK -

Not OK -

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Checking fuel tank pressure sensor

- Go into scrolling values.
- Read off fuel tank pressure and canister purge (CP) valve value.

When the canister purge (CP) valve opens fuel tank pressure should drop.

OK -

Not OK -

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Checking fuel tank pressure sensor hose

- Ignition off.
- Remove fuel tank pressure sensor according to Tank pressure sensor, replacement Removal and Replacement.
- Remove hose with Y-nipple.
Check that the nipple and hoses are not blocked.

Are they blocked?

Yes - Remedy or replace. Then continue with.

No - Try a new fuel tank pressure sensor. Then continue with.

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Checking hose to EVAP canister shut-off valve
- Remove left fender liner.
Check hose to EVAP canister shut-off valve seal and check connectors.

Is the hose OK?

OK - Try a new EVAP canister shut-off valve. Then continue with.

Not OK - Remedy or replace hose. Then continue with.

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Checking hose
- Remedy or replace hose.

Continue -

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Checking fuel tank system
- Ignition off.
- Carefully pressurize the fuel tank system to 7 kPa.

Note! Max 10 kPa.

Check fuel tank system by spraying soapy water from the EVAP canister to the canister purge (CP) valve. Spray the line between the fuel tank, pressure regulator and roll-over valve. Check filler pipe and fuel tank filler cap.
It may be necessary to lower the fuel tank in order to fault-trace hoses and connectors on top of the fuel tank.
Remedy leakage.

Continue -.

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Replacing component
- Try a new fuel tank pressure sensor.

Continue -

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Replacing or repairing component
- Remedy or replace hose or nipple.

Continue -

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Checking fuel tank system

- Ignition off.
- Carefully pressurize fuel tank system to 7 kPa.

Note! Max 10 kPa

- Check the fuel tank system by spraying it with soap solution. From the EVAP canister to the canister purge (CP) valve and on the line to the fuel tank with the pressure regulator and roll-over valve. Check filler pipe and fuel tank filler cap.
- It may be necessary to lower the fuel tank in order to fault-trace hoses and connectors on top of the fuel tank.

Continue -

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Verification

Verification

Hint: After carrying out the repair, check that the fault has been remedied as follows:

- Ignition off.
- Reinstall all hoses/components.
- Ignition on.

- Select Volvo Scan Tool (ST) to erase diagnostic trouble codes (DTCs).

Continue - Verification, continued

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Verification, continued

- Disconnect the Volvo Scan Tool (ST) from the VIDA station and use it in stand-alone mode.
- Run the engine to operating temperature (above 70°C).
- Air conditioning (A/C) off.
- Gear selector in P or N
- Engine idling
- Go into the Diagnostic Test Mode (DTM) menu. Activate leak diagnostic.
- Wait until the diagnostic is complete. This can take up to 2 minutes.

Note! If the texts START CONDITIONS NOT MET or DIAGNOSTIC INTERRUPTED are displayed the diagnostic cannot be carried out. This can have several causes: for example high fuel evaporation, high canister charge, high tank pressure, fuel trim not active or a diagnostic trouble code (DTC) stored after the diagnostic has been activated. Check that no diagnostic trouble codes (DTCs) stored, try to activate the diagnostic again. Sometimes several attempts will have to be made before the diagnostic is carried out.

Continue - Verification, continued

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Verification, continued

- Volvo Scan Tool (ST) connect to VIDA station.
- Engine idling

- Select Volvo Scan Tool (ST) to read off diagnostic trouble codes (DTCs).

Does the diagnostic trouble code (DTC) recur?

Yes - VERIFICATION FAILED

No - VERIFIED

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VERIFIED - FAULT FOUND

VERIFICATION FAILED -

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Fault-tracing information

Information

Fault-tracing information
The fault should have been detected and remedied. As this is not the case fault-tracing has failed.
Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Do you want to exit fault-tracing?

Yes - Exit fault-tracing

No - Attempt New Test

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Attempt New Test -

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Safety
First read Safety regulations for handling fuel Safety Regulations For Handling Fuel.

Continue - Checking cables and terminals

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Checking cables and terminals
Check that the fuel tank filler cap is on properly and that its seal is intact.
Check hoses and hose connectors at the EVAP canister, EVAP canister shut-off valve and fuel tank.

Were any faults detected?

Yes - Remedy the fault

No - Checking vacuum downstream of the canister purge (CP) valve

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Remedy the fault
Remedy the fault

Continue - Verification

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Checking vacuum downstream of the canister purge (CP) valve

- Start the engine and let it idle.
- Disconnect the hose between the canister purge (CP) valve and EVAP canister from the canister purge (CP) valve.
Check that there is vacuum in the canister purge (CP) valve when the valve is activated.

Is there a vacuum?

Yes - Checking vacuum at EVAP canister

No - Checking vacuum to canister purge (CP) valve

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Checking vacuum at EVAP canister

- Ignition off.
- Reinstall hose on canister purge (CP) valve.
- Disconnect hose to canister purge (CP) valve from EVAP canister.
- Start the engine and let it idle.
- Read off fuel tank pressure and canister purge (CP) valve value.
Check that there is vacuum in the hose when the canister purge (CP) valve is activated.

Is there a vacuum?

Yes - Checking EVAP canister

No - Checking hose

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Checking vacuum to canister purge (CP) valve

- Connect hose between canister purge (CP) valve and EVAP canister to canister purge (CP) valve.
- Start the engine and let it idle.
- Disconnect hose between canister purge (CP) valve and intake manifold from the canister purge (CP) valve.
Check that there is a vacuum in the hose.

Is there a vacuum?

Yes - Replacing component

No - Checking hose

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Replacing component
Try a new canister purge (CP) valve.

Continue - Verification

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Checking hose
Check if the hose between the canister purge (CP) valve and intake manifold is blocked. Check the hose connection to the intake manifold.

Continue - Verification

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Checking EVAP canister
Check that all EVAP canister inlets and outlets are airtight.

Are all inlets and outlets airtight?

Yes - Replacing component

No - Checking hose between fuel tank and EVAP canister

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Checking hose
Check if the hose between the canister purge (CP) valve and EVAP canister is blocked or trapped.

Continue - Verification

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Replacing component
Remedy or try a new EVAP canister according to Replacing the EVAP canister Replacing the EVAP Canister.

Continue - Verification

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Checking hose between fuel tank and EVAP canister
Check that the hose between the fuel tank and EVAP canister is airtight and is not trapped.

Was a fault detected?

Yes - Replacing or repairing component

No - Test pressurization of the fuel tank system

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Replacing or repairing component
Remedy or replace hose between fuel tank and EVAP canister.

Continue - Verification

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Test pressurization of the fuel tank system

- Max 30 liters (7.93 US gal.) of fuel in the fuel tank.
- Ignition off.
- Connect hose from fuel tank to EVAP canister.
- Clamp hose between EVAP canister shut-off valve and EVAP canister with a hose clip to seal it off.
- Carefully disconnect the EVAP canister hose from the canister purge (CP) valve.
Connect manometer 999 5646 Pressure gauge 999 5646 Pressure Gauge to hose and pressure regulator 999 5544 REGULATOR 999 5544 Regulator to manometer.
Set pressure to 7 kPa (1.02 psi) (read off on the manometer 999 5646 Pressure gauge 999 5646 Pressure Gauge ).
Cock at right angles to the hoses.

Warning! Max 10 kPa (1.45 psi).

Let the pressure build up for 5 minutes.
Shut off the cock (the pressure may drop 1-2 kPa (0.14 - 0.29 psi) before stabilizing) and read off pressure.
EVAP canister hose cock.
Wait for 10 minutes.

Warning! Never leave the car unattended with its fuel tank system pressurized.

The pressure should be stable (it may rise a little due to fuel evaporation).

Is the pressure stable?

Yes - Checking fuel tank pressure sensor

No - Checking fuel tank system

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Checking fuel tank pressure sensor

- Disconnect tool 999 5646 Pressure gauge 999 5646 Pressure Gauge.
- Connect EVAP canister hose.
- Remove hose clamp from hose between canister purge (CP) valve and intake manifold.
- Start the engine and let it idle.
- Read off fuel tank pressure and canister purge (CP) valve value.
When the canister purge (CP) valve opens the pressure in the fuel tank should drop.

Is pressure in the fuel tank dropping?

Yes - Checking hose to EVAP canister shut-off valve

No - Checking fuel tank pressure sensor hose

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Checking hose to EVAP canister shut-off valve
Check hose to EVAP canister shut-off valve seal and check connectors.

Is the hose OK?

Yes - Replacing component

No - Replacing or repairing component

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Checking fuel tank pressure sensor hose

- Ignition off.
- Remove fuel tank pressure sensor. Replacing fuel tank pressure sensor Removal and Replacement.
- Remove hose with Y-nipple.
Check that the nipple and hoses are not blocked.

Are the nipple and hoses blocked?

Yes - Replacing or repairing component

No - Replacing component

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Replacing or repairing component
Remedy or replace hose or nipple.

Continue - Verification

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Replacing component
Try a new fuel tank pressure sensor according to Replacing fuel tank pressure sensor Removal and Replacement.

Continue - Verification

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Replacing component
Try a new EVAP canister shut-off valve.

Continue - Verification

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Replacing or repairing component
Remedy or replace hose.

Continue - Verification

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Checking fuel tank system
- Ignition off.
- Carefully pressurize the fuel tank system to 7 kPa (1.02 psi). Cock at right angles to the hoses.

Note! Max 10 kPa (1.45 psi).

Check fuel tank system by spraying soapy water from the EVAP canister to the canister purge (CP) valve. Spray the line between the fuel tank and EVAP canister shut-off valve. Check filler pipe and fuel tank filler cap.
It may be necessary to lower the fuel tank in order to fault-trace hoses and connectors on top of the fuel tank.
Remedy leakage.

Continue - Verification.

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Verification

Verification

Hint: After carrying out the repair, check that the fault has been remedied as follows:

- Ignition off.
- Reinstall all hoses/components.
- Erase diagnostic trouble codes (DTCs).
- Run the engine to operating temperature (above 70 °C (158 °F)).
- Air conditioning (A/C) off.
- Gear selector in P or N
- Engine idling
- Go into diagnostic test menu. Select leakage diagnostic.
- Wait until the diagnostic is complete. This can take up to 2 minutes.
Read off diagnostic trouble codes (DTCs).

Note! If the texts START CONDITIONS NOT MET or DIAGNOSTIC INTERRUPTED are displayed the diagnostic cannot be carried out. This can have several causes: for example high fuel evaporation, high canister charge, high tank pressure, fuel trim not active or a diagnostic trouble code (DTC) stored after the diagnostic has been activated. Check that no diagnostic trouble codes (DTCs) are stored, restart the car and try to activate the diagnostic again. Sometimes several attempts will have to be made before the diagnostic is carried out.

Does the diagnostic trouble code (DTC) recur?

Yes - VERIFICATION FAILED

No - VERIFIED

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VERIFIED - FAULT FOUND

VERIFICATION FAILED - Fault-tracing information

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Fault-tracing information
Information
Attempt New Test - Checking cables and terminals

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