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DIY 1997 Volvo 855 Roll-over Valve Hose Replacement Topic is solved

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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jreed
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Volvo Repair Database DIY 1997 Volvo 855 Roll-over Valve Hose Replacement  Topic is solved

Post by jreed » Sun Jun 21, 2015 3:49 pm

The past few times I've tried to fill up the gas tank the pump keeps shutting off after just a few seconds, no matter how slow you try to pump in the fuel. It took me a while to finally get the tank full. This is new behavior for this car. As part of the diagnosis, I decided to check out the roll over valve to make sure that it was allowing the vapor from the tank to pass through to the charcoal canister during fueling. I had worked on the hoses about 7 or 8 years ago after a squirrel or some other critter had eaten through them, setting off a P0455 code. I had replaced the nibbled hoses and wrapped the most exposed one of them with aluminum duct tape. Here you can see the roll over valve and hoses after I removed them from the car.
IMG_9347.jpg
Old hoses, one with duct tape "squirrel proofing" wrapped around it
IMG_9347.jpg (101.76 KiB) Viewed 951 times
I inspected the hoses and found a hard white debris partially blocking the outlet (upper) hose. I don't know what the debris was but it looked like it might be blocking the passage of vapor. I had also used some black electrician's tape on the nipples to increase their diameter to make a better fit with the fuel line that I had used before... I suspect that the tape might have moved and partially blocked off the nipples.
IMG_9349.jpg
Debris blocking the hose
IMG_9349.jpg (69.64 KiB) Viewed 951 times
I noticed the roll over valve is marked "Can Vent" and has a Chrysler pentagon symbol on it... interesting. I think the charcoal canister has a "GM" label.
IMG_9350.jpg
Chrysler symbol on top of roll over valve
IMG_9350.jpg (82.53 KiB) Viewed 951 times
After cleaning up the ends, I tested the operation of the roll over valve by blowing through the lower pipe to verify that it was allowing air to pass and then tilting the valve on it's side and upside down to verify that it blocked the air. Then, I oriented it upright again and verified that it started allowing air to pass again.

Next I proceeded to install new hoses on the hard lines. I used 6mm ID silicone hose, which isn't the best choice for fuel vapor but it has the advantage that it can stretch -- this is helpful because the roll over valve nipples have a smaller diameter than the black plastic hard lines. The nipples are about 6mm and the black plastic hard line is about 7 or 8mm.
Outlet (upper) hard line:
IMG_9352.jpg
Outlet hard line
IMG_9352.jpg (95.16 KiB) Viewed 951 times
Hose installed on line:
IMG_9353.jpg
Hose installed on upper line
IMG_9353.jpg (109.55 KiB) Viewed 951 times
Inlet (lower) hard line:
IMG_9351.jpg
Inlet (lower) hard line
IMG_9351.jpg (95.06 KiB) Viewed 951 times
Hose installed on both lines:
IMG_9354.jpg
Hoses installed on both hard lines
IMG_9354.jpg (83.83 KiB) Viewed 951 times
Once you have the lines installed, trim the upper line to the right length and attach it to the roll over valve. To improve access, do this before you reattach the roll over valve to the car. Install a zip tie to hold the hose on the nipple.
IMG_9355.jpg
Attach upper line to roll over valve
IMG_9355.jpg (90.92 KiB) Viewed 951 times
Then reattach the roll over valve bracket to the car. On my car, it is a 12mm bolt:
IMG_9357.jpg
Reattach 12mm bolt holding roll over valve bracket to car
IMG_9357.jpg (102 KiB) Viewed 951 times
Then trim the lower line to the right length:
IMG_9358.jpg
Trim the lower line to the right length
IMG_9358.jpg (89.66 KiB) Viewed 951 times
And slide the line over the lower nipple:
IMG_9359.jpg
Slide lower line over lower nipple
IMG_9359.jpg (96.13 KiB) Viewed 951 times
Install and trim a zip tie to hold the lower line in place on the nipple:
IMG_9360.jpg
Install and trim a zip tie to hold line
IMG_9360.jpg (91.07 KiB) Viewed 951 times
Here is the completed installation:
IMG_9362.jpg
Completed installation
IMG_9362.jpg (96.57 KiB) Viewed 951 times
I'm looking forward to trying to fill up with fuel next time to see if this repair helps make it go smoothly.
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Hansvolvo
1997 855 GLT (Light Pressure Turbo) still going strong. Previous: 1986 240 GL rusted out in '06, 1985 Saab 900T rusted out in '95, 1975 Saab 99 rusted out in '95, 1973 Saab 99 rusted out in '94

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Re: DIY 1997 Volvo 855 Roll-over Valve Hose Replacement

Post by matthew1 » Sat Feb 01, 2020 7:54 am

Entered into the VRD. Thanks JReed.
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1997 850 T5, MSD ignition coil, Hallman manual boost controller, injectors, R bumper, OMP strut brace [gone]
2004 V70 R [gone]

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Re: DIY 1997 Volvo 855 Roll-over Valve Hose Replacement

Post by smacknab » Sat Feb 01, 2020 11:48 am

Thanks for writing this up, do you know if the 99 has the same valve? On my car the carbon canister is back here too, by the fuel filter
99 s70 NA m56 - >213k miles

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abscate
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abscate

Re: DIY 1997 Volvo 855 Roll-over Valve Hose Replacement

Post by abscate » Sat Feb 01, 2020 2:40 pm

smacknab wrote:
Sat Feb 01, 2020 11:48 am
Thanks for writing this up, do you know if the 99 has the same valve? On my car the carbon canister is back here too, by the fuel filter

Part 8 in this diagram

Part number 1255422, not showing available there but worth a google
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Re: DIY 1997 Volvo 855 Roll-over Valve Hose Replacement

Post by erikv11 » Sun Feb 02, 2020 8:06 am

All P80 cars have that rollover valve in the back near the fuel filter.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 286k
'06 S60 R, 167k
'99 Camry V6 :shock: 125k
gone: '96 NA 850 210k, '98 NA V70 182k

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