Fuel tank filler cap. Checking seal

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Special tools:

9995757

Checking the sealing ring in the fuel tank filler cap

Fig 1: Checking Sealing Ring In Fuel Tank Filler Cap

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check that the sealing ring (1) in the fuel tank filler cap is intact, is correctly positioned and has a clean mating surface.

The temperature of the fuel tank filler cap must be 20°C +/- 10°C (68°F +/- 18°F).

The leak test below checks the elasticity of the rubber and for cracks and material wear

Use tool 9995757 for the seal test.

Checking hoses for the vacuum pump and fuel filler cap adapter

Fig 2: Checking Hoses For Vacuum Pump And Fuel Filler Cap Adapter

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check that the hoses for the vacuum pump and fuel filler cap adapter are securely installed.

Check the vacuum pump for leaks

Fig 3: Checking Vacuum Pump For Leaks

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check the vacuum pump for leaks by blocking the hole in the adapter with a finger and pumping out the air. There should be no increase in pressure.

Repeat the above, this time with overpressure. There should be no reduction in pressure.

Installing the fuel filler cap

Fig 4: Checking Pressure Valve In Fuel Tank Filler Cap

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the fuel filler cap to the adapter. Turn until you hear a click

Leak test, vacuum

Fig 5: Leak Test, Vacuum

Courtesy of VOLVO CARS OF NORTH AMERICA.

Set the selector to position VACUUM.

Slowly pump out the air to minus (-) 3 kPa. Wait until the vacuum has stabilized. Pressure increases of 1 kPa per 30 seconds are permitted.

Replace any fuel filler cap that fails this test.

Testing vacuum valve

Fig 6: Testing Vacuum Valve

Courtesy of VOLVO CARS OF NORTH AMERICA.

Pump air out until the vacuum valve opens. This should occur between minus (-) 4 and minus (-) 12 kPa.

Leak test, pressure

Fig 7: Leak Test, Pressure

Courtesy of VOLVO CARS OF NORTH AMERICA.

Set the selector to position PRESSURE.

Slowly pump in the air to plus (+) 3 kPa. Wait until the pressure has stabilized. Pressure reductions of 1 kPa per 30 seconds are permitted.

Replace any fuel filler cap that fails this test.

Testing relief valve

Fig 8: Testing Relief Valve

Courtesy of VOLVO CARS OF NORTH AMERICA.

Pump air in until the relief valve opens. This should occur between plus (+) 14 and plus (+) 30 kPa.