1999 T6 - Major leak in Evap. system

keithatcpt · Post by **keithatcpt** » 13 Oct 2009, 08:03

I've got a 1999 S80 T6 (145k mi) that had a CEL from a "Major Leak" in the evap system. I looked around and found a large vacuum line that had been pulled apart. I pushed that back together and reset the CEL with my ODBII code reader (invaluable when working on Volvos). Now, after two weeks of driving, no CEL is present, but the emissions readiness indicator is still indicating a problem with the evap system. Should I be trying to troubleshoot the evap system still, or is there another place I need to reset. Unplug the battery for a while to reset something?

- Keith

eM3RgE · Post by **eM3RgE** » 26 Oct 2009, 11:32

Which vacuum line was the culprit? Usually codes can be cleared through the reader itself, but if no CEL light turned on then usually means that it has been resolved.

keithatcpt · Post by **keithatcpt** » 27 Oct 2009, 06:52

I found a crack in the "J" tube at the charcoal canister that you could fit a dime through. I put a temporary patch on the crack with duct tape (the handyman's secret weapon) and a hose clamp, but I still am getting a CEL. The purge valve is good. Still looking for what might be causing the problem.

- Keith

syrotchen · Post by **syrotchen** » 02 Nov 2009, 15:49

It sounds like you may still be leaking through your patch? However, I had the same error on my wife's xc70 though and took a quick look at the gas cap and noticed the oring was cracked and had a few pieces even missing. A quick replacement of the gas cap cleared up the issue.

Jsibilia · Post by **Jsibilia** » 03 Nov 2009, 12:13

I replaced my gas cap as well. Had a P2407 code on my 03 S80 2.5 Normal asperated engine with 103 thou. miles. Looked at it carefully and noticed cracks and low grip pressure on seat. After replacing it, the CEL came on again after two days. Looked at all the lines and tried to scan the canister above the rear crossmember which was near impossible.

I would also second guess the duct tape repair myself. Was the line plastic and you said you also used a hose clamp??? The Slightest clamp pressure I'm sure would create another breach in the line.

I did clear the memory of my ECM with my OBDII reader and I also disconnected the battery. I cycled the ignition switch several times to clear any carbon deposits on the electrical contacts. It worked after that.
Also, Volvo came out with an extended warranty P45 campaign to 120 thou mi. You've exceeded that. The dealership alters the parimeters of the ECM. Good luck!

keithatcpt · Post by **keithatcpt** » 30 Nov 2009, 14:45

I replaced my "J" hose and found cracks on both ends of the hose. I had coated the "bend end" of the J hose with silicone, but the other end of the hose was cracked as well and is impossible to get to without dropping the exhaust. The CEL never came back after a reset.

- Keith

Post by **dcarlson12** » 30 Nov 2009, 14:58

Keith:
Me again over from the seat question. The reason I want to remove the seat is to get at the sender unit and pump areas on top of the tank. I believe by gas fume smell and my slow evaporative leak are likely coming from a connection/interface on top of the fuel tank. I checked under the car while lying on my back and using a mirror I couldn't find any signs of a crack in the 'J' hose but there appears to be signs of 'residual' fuel along the bottom of the 'left' portion of the fuel tank right below where the sender unit and line to the charcoal canister originate on the fuel tank.

If I get the seat out, will I have access to the 'hose' which runs from the tank to the charcoal canister? Am hoping it just be a leak in a seal/gasket/'o'ring between the sender unit and the top of the tank or ????

keithatcpt · Post by **keithatcpt** » 30 Nov 2009, 15:21

I also removed the ports over the gas tank. When I removed the port on the right side of the car, there was also a slow leak on the top of the gas tank. It was a tiny pinhole leak. You might have the same problem. I don't think it was enough to cause a drop in vacuum level, but it was causing a very detectable odor.

You won't see the cracks in the J hose until you get it off, as I found. It's a real pain to replace, but that was definitely my problem. I also replaced my gas cap, but that didn't seem to help or hurt.

- Keith

Avkidd · Post by **Avkidd** » 26 Apr 2014, 12:43

I also have a large evap leak in my 01 s80 t6 the only thing i changed so far is the gas cap but the car is drinking gas like water …..i also have a taping sound every now and then wondering if it has anything to do withe evap problem …. but where should i start

keithatcpt · Post by **keithatcpt** » 26 Apr 2014, 15:07

My t6 is long gone, but if you smell any gas, check top of the tank under the rear seat. The top of the fuel tank had a small leak. Start there and with the j tube, that was my problem when I had the car.