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EVAP hose?

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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rick4484
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Re: EVAP hose?

Post by rick4484 »

I managed to build a hose that replaces the stock hose. The stock hose, which is discontinued now, is unique in that it has a large end and a smaller end. I measured the inside diameter of the original hose and it appears to be 18mm x 11mm. So, to accomplished this repair, if you cannot locate a decent stock hose from a pick-n-pull, some place in Europe, or have one custom made ($$$), you'll have to make one.

I obtained a barbed brass adapter 5/8" x 3/8" from Amazon. https://www.amazon.com/Beduan-Reducing- ... F0aWM&th=1

I couldn't find any 18mm I.D. rubber fuel hose locally and I did not want to wait for a shipment, so I went with 5/8" I.D. This size hose will not fit onto the blue fitting at the tank without enlarging one end. I used a heat gun and a Torx socket body (Harbor Freight) secured in a vice to form the larger end. It took several sessions of applying heat to the hose and forcing the hose over the socket body. When it cools it may look like it has returned to is original size but it should slide over the fitting with the help of a little silicone grease. The other end of the 5/8" hose will fit over the brass adapter without modification.
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I did manage to find 11mm I.D. fuel hose at O'reilly's Part #27005. This hose will fit the fuel line but will be slightly larger than the 3/8" brass adapter. I simply tightened the hose clamp down until it was secured to the adapter.

I disconnected the positive lead from the car battery.
From inside the car remove the plates that cover the fuel pump, and disconnect the electrical connectors from plugs located under the interior wall at the passenger side of the trunk. I popped off the two fuel lines and disconnected the fuel neck from the body. (See other posts for more detail on how to do drop the tank)

This repair was done with 3 - 4 gallons of fuel in the tank and required the passenger rear of the vehicle to be raised. I blocked the front wheels and used a floor jack to raise the passenger rear side. I slid a ramp under the right rear wheel, and placed a jack stand under a cross member for added safety.

I placed a floor jack under the tank, and using thick folded cardboard to protect from damaging the tank, slowly lower the tank until you have working room. (Have some 4 x 4 wood supports on the floor under the tank to keep the tank off the floor. This will make it easier to reposition the floor jack if you have to lower it completely)

Remove the hose shown in my original post, two hose clamps.
Once you've made your replacement hose, you're ready to install in reverse order. The hardest part I had was getting the tank strap on the passenger side back in place to bolt it on. With some finesse, with help of the floor jack, it finally went back into position and I secured it.
I lowered the car, reconnected the battery and started the car. My Check Engine Light was out, but this is typical after the battery has been disconnected for some time. If the problem is still present (P0445) the CEL may return in a few days or within a week of driving. I'll have more confidence in this repair after a few weeks on the road. My code reader does not indicate any codes at this time.
Last edited by rick4484 on 25 Nov 2024, 16:41, edited 2 times in total.

scot850
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Year and Model: 2000 V70 R
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Post by scot850 »

Fingers crossed this has fixed the pesky issue! Thanks for the update and solution.

Neil.
2006 V70 2.5T AWD Polestar tune
2000 V70 R - still being an endless PITA
2006 XC70 - Our son now has this and still parked in our garage
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L - Sold
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - Sold

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