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DTC 611: Fuel Tank System, Large Leak

  1. Check status message on Volvo Scan Tool (998-8686 ). If fault is PERMANENT, LARGE LEAK, perform all procedures in next step. If fault is INTERMITTENT, LARGE LEAK, check for defective components as outlined in next step.
  2. Ensure fuel tank filler cap is on correctly and seal is intact. Check EVAP canister, rollover valve, EVAP canister shut-off valve and fuel tank hoses, and hose connectors. Repair as necessary. If no faults are found, go to next step.
  3. Start and idle engine. Disconnect hose between CP valve and EVAP canister from Canister Purge (CP) valve. Using scan tool, go into scrolling values. Read off CP valve value to determine whether valve is active or not active. If there is vacuum in CP valve when valve is activated, go to step 5). If there is no vacuum, go to next step.
  4. Reconnect hose between CP valve and EVAP canister to Canister Purge (CP) valve. Start and idle engine. Disconnect hose between CP valve and intake manifold from CP valve. If vacuum is present in hose, replace CP valve. If vacuum is not present, check if hose is blocked or disconnected.
  5. Turn ignition off. Reinstall CP valve. Disconnect hose between CP valve and EVAP canister. Start and idle engine. Using scan tool, go into scrolling values list. Read off CP valve value to determine if valve is active or not active. If there is vacuum in CP valve when valve is activated, go to next step. If there is no vacuum, check if hose is blocked or disconnected.
  6. Ensure all EVAP canister inlets and outlets are airtight. If inlets and outlets are airtight, go to next step. If inlets and outlets are not airtight, repair as necessary.
  7. Disconnect hose to fuel tank from EVAP canister. Connect vacuum pump to hose. Operate vacuum pump. If it is not possible to pump up vacuum, go to next step. If it is possible to pump up vacuum, check that rollover valve is airtight. Ensure hose between fuel tank and EVAP canister is airtight. Repair as necessary.
    NOTE: Following step pressurizes fuel tank. Ensure tank does not contain more than 8 gallons of fuel.
  8. Ensure ignition is off. Connect hose from fuel tank to EVAP canister. Remove EVAP canister shut-off valve from its bracket. Clamp hose between EVAP canister shut-off valve and EVAP canister Carefully disconnect EVAP canister hose from CP valve. Connect Pressure Gauge (999 5646) to hose and Pressure Regulator (999 5544) to pressure gauge. Set pressure at one psi (.07 kg/cm2 ). Open cock valve on pressure gauge. Let pressure build for 5 minutes, ensuring pressure does not increase beyond maximum 1.4 psi (.09 kg/cm2 ). Shut off cock valve. Pressure may drop .15-.30 psi (.01-.02 kg/cm2 ) before stabilizing. Read off pressure. Wait 10 minutes.
  9. If pressure does not stabilize, go to step 11). If pressure stabilizes, disconnect pressure gauge. Reconnect EVAP canister hose. Remove hose clamp from hose between CP valve and intake manifold. Start and idle engine. Using scan tool, read off fuel tank pressure and CP valve value. If fuel tank pressure does not drop when CP valve opens, go to next step. If fuel tank pressure drops when CP valve opens, ensure hose to EVAP canister shut-off valve is airtight. Repair as necessary. If hose and connectors are okay, replace EVAP canister shut-off valve.
  10. Turn ignition off. Remove fuel tank pressure sensor located in front of fuel pump. Check all hoses and nipples for blockage. Repair as necessary. If hoses are okay, replace fuel tank pressure sensor.
  11. Ensure ignition is off. Pressurize fuel tank as outlined in step 8). Spray soapy water on fuel tank, fuel hoses and other components. It may be necessary to lower fuel tank to gain access to hoses and connectors on top of tank. Repair as necessary.
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