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  1. #1
    Veteran Member Four Rings christianb5s4's Avatar
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    Still Battling EVAP Issue

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    Got the car back and while it's running great, the few things I did to tackle the EVAP leak issue did not solve the problem. Here's what's been done:

    - New EVAP purge valve
    - New line and check valve to the purge valve
    - New gas cap
    - All lines on the engine side inspected and tested for leaks
    - New PCV, oil separator, etc.


    Unfortunately the EVAP code came back, however here are a few symptoms in case this gives ya'll any ideas on what the cause might be. Codes that come back are always P0441 and P0455:

    - It comes back as soon as the car gets down to a 1/4 tank of gas
    - Still has a hard time starting after gassing up but the tank fills just fine so I don't think it's a charcoal canister issue
    - Can smell gas strongly outside the car while filling the tank with gas, however no visible leaks

    Did some more research and it's all pointing to the leak detection pump. Does anyone have feedback?
    Last edited by christianb5s4; 04-23-2018 at 09:43 AM.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  2. #2
    Veteran Member Four Rings SinCityA6's Avatar
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    '07 Mustang GT Tungsten Grey/Black
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    I am having a similar issue. VCDS is registering a very small EVAP leak and every time I fill my tank, I smell gas fumes outside the car until the tank falls below 3/4. Iím thinking it is either the charcoal canister of the leak detection pump.


    Sent from my iPhone using Audizine
    '09 C6.5 A6
    M: 3.0t, GIAC/AWE Stg II+, Roc*Euro Intake
    I: Soul Black, CF Trim, LEDs, Paddles, C7 Shifter, Escort 9500i, Blackvue Dashcam
    E: Ibis White, 15% Tint, Smoked Corners, Tinted Tails, S4 Rockers, S6 Blades, RS6 Grill, OEM Splitters (F/R)
    S: H&R Springs/Sways, Koni FSDs, Adams Rotors, Akebono Pads, SS Brake Lines, Paint Matched Calipers, Niche Misano M116 Wheels

  3. #3
    Veteran Member Three Rings cal3thousand's Avatar
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    Gas cap could be causing those codes. How confident are you in the gas cap's condition?
    Danton Black: 2009 Audi C6.5 A6 Sedan (Quattro, 3.0T, Prestige)
    I miss my Avant, longing for a 2011 3.0T
    Dead:
    Griselda, aka Grizzy: 2007 Audi C6 A6 Avant (Quattro, S-Line)

    Just some small cosmetic mods while getting to Stage 0

    Need MMI 2G High update info? PM me.

  4. #4
    Veteran Member Four Rings christianb5s4's Avatar
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    It has to be one of those two, the charcoal canister is easy enough to change since it's super easy to access in the back of the car but I am more worried about the leak detection pump due to where it's located. Forgot to mention but I also threw a brand new OEM gas cap as the first thing I tried, which didn't do a thing of course since that would be too easy. *sarcasm*
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  5. #5
    Veteran Member Four Rings SinCityA6's Avatar
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    '07 Mustang GT Tungsten Grey/Black
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    Quote Originally Posted by cal3thousand View Post
    Gas cap could be causing those codes. How confident are you in the gas cap's condition?
    For me, the gas cap was the first thing I swapped out. No change.


    Sent from my iPhone using Audizine
    '09 C6.5 A6
    M: 3.0t, GIAC/AWE Stg II+, Roc*Euro Intake
    I: Soul Black, CF Trim, LEDs, Paddles, C7 Shifter, Escort 9500i, Blackvue Dashcam
    E: Ibis White, 15% Tint, Smoked Corners, Tinted Tails, S4 Rockers, S6 Blades, RS6 Grill, OEM Splitters (F/R)
    S: H&R Springs/Sways, Koni FSDs, Adams Rotors, Akebono Pads, SS Brake Lines, Paint Matched Calipers, Niche Misano M116 Wheels

  6. #6
    Active Member Two Rings snowzach's Avatar
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    I had the code and played with some of the solenoids. I replaced the one under the rings cover with a short "S" shaped hose. The Oring was really old and didn't seal well. There was also dust in the hole. I replace the solenoid and smeared some thick bearing grease in the hole to help it seal. That fixed mine. I don't know if that's the evap solenoid but it was the one causing my issue...

    More importantly did the PCV replacement fix oil consumption problems?

  7. #7
    Veteran Member Four Rings christianb5s4's Avatar
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    Too soon to tell on the oil consumption, granted I didn't measure consumption before it was replaced so I can't tell you what change it made. After a bit more time I'll let you know if I have an issue or not!

    I replaced the EVAP valve with a brand new OE part from the deal which is this one as well as the breather hose that connects to that valve which has an integrated check valve:




    However the reason I believe it's either the leak detection pump and/or the charcoal canister is because the system on block 070 passes the test when the tank is 1/2-full but the codes come back as the tank gets lower, the hard start after filling up as well as smelling fuel vapors while pumping the gas also remained. However I do not have issues with the pump stopping and fills normally.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  8. #8
    Active Member Two Rings snowzach's Avatar
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    Yah, that's the one I replaced that fixed my problem. Sorry man good luck hope you solve it. Report back on oil consumption if you could. That's one I want to tackle this summer.

  9. #9
    Veteran Member Four Rings christianb5s4's Avatar
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    That EVAP valve and line fixed the sporadic flow code I had, but the large leak codes remained although they don't come back as quickly. Does anyone have a guide, pictures or DIYs related to the leak detection pump on these cars by chance?
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  10. #10
    Veteran Member Four Rings christianb5s4's Avatar
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    So I replaced the whole leak detection pump assembly and checked all the lines related to that, the charcoal canister and the lines around the filler neck. Smoke tested and could not find any leaks but the car still has the following codes:

    P0441: EVAP Emission Control Sys: Incorrect Flow
    P0455: EVAP System: Large Leak Detected

    Things I've done so far:

    - New purge/N80 valve
    - New breather hose and check valve
    - New leak detection pump assembly

    I can still smell gas after filling up and the car takes one or two tries to start after fill up. Anyone have any other leads on what to look at next?
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  11. #11
    Veteran Member Four Rings christianb5s4's Avatar
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    Any ideas? Otherwise I'm going to take it back to the shop and have them deal with it.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  12. #12
    Active Member Two Rings 11A6's Avatar
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    I've got nothing to add - curious as to the resolution.
    2011 A6 Avant Prestige w/CWP 1/20

  13. #13
    Veteran Member Four Rings itsmatt33's Avatar
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    Random question, do you have an aftermarket stereo or sub installed? check where the ground was drilled in.
    GTX2867r Audi A4 B6 TQM RECARO|HRE|ER|IE|APR|AWE|034 Build page here
    Daily Driven Audi Q3 Neuspeed|HRE|REMUS|KW Build page here
    IG: @matthewee

  14. #14
    Veteran Member Four Rings christianb5s4's Avatar
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    The biggest clue I have is that I can smell gas when I pump the car up, I smoke tested the lines at the filler neck area but didn't find leaks. I'm guessing it's the charcoal canister but I want to find a way to test it first before dropping $250 on it.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  15. #15
    Veteran Member Four Rings ichi d's Avatar
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    Don't have much to add but did u try and change your fuel filter?
    C7 4.0T - EPL stage 1 ECU/TCU.

    Donated - C6.5 Apr Stage 2

  16. #16
    Veteran Member Four Rings christianb5s4's Avatar
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    I have not replaced it, I can't imagine it's too much harder to do than my B5 S4 though. I'm also going to inspect the fuel pump assembly as I found a thread about someone who had a leak there that could be a source of an evap leak.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  17. #17
    Veteran Member Four Rings christianb5s4's Avatar
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    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  18. #18
    Veteran Member Four Rings christianb5s4's Avatar
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    Progess: installed a new OEM charcoal canister last night, smoke tested all the lines at the back of the car and found no leaks. First thing I did was go to the gas station and fill the tank to see if the car had a hard start. It did, however for the first time since I bought it it actually stayed running instead of starting then stalling then having to restart it again.

    The bigger learning is I pinpointed the area where the gas smell is coming from which is the front passenger side fender and/or engine intake area. Just smell which goes away quickly, no visible leaks. What lines are in that area that are fuel or evap related?
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  19. #19
    Veteran Member Three Rings cal3thousand's Avatar
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    Quote Originally Posted by christianb5s4 View Post
    Progess: installed a new OEM charcoal canister last night, smoke tested all the lines at the back of the car and found no leaks. First thing I did was go to the gas station and fill the tank to see if the car had a hard start. It did, however for the first time since I bought it it actually stayed running instead of starting then stalling then having to restart it again.

    The bigger learning is I pinpointed the area where the gas smell is coming from which is the front passenger side fender and/or engine intake area. Just smell which goes away quickly, no visible leaks. What lines are in that area that are fuel or evap related?
    The HPFP is run off the passenger side intake cam lobe. The hard line runs from there to the SC valley and to the injectors. Maybe you have an injector leak or pump leak? (not sure how that would affect EVAP codes... just a guess at the moment)
    Danton Black: 2009 Audi C6.5 A6 Sedan (Quattro, 3.0T, Prestige)
    I miss my Avant, longing for a 2011 3.0T
    Dead:
    Griselda, aka Grizzy: 2007 Audi C6 A6 Avant (Quattro, S-Line)

    Just some small cosmetic mods while getting to Stage 0

    Need MMI 2G High update info? PM me.

  20. #20
    Veteran Member Four Rings christianb5s4's Avatar
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    No injector leaks, those all have brand new seals after doing the oil separator/PCV line/thermostat. Smell does not come from the intake valley, only from the passenger wheel well area.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  21. #21
    Veteran Member Four Rings christianb5s4's Avatar
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    I narrowed down where the gas smell was coming from, it's where the two hoses that lead from the HPFP and the vent tube from the intake meet the hard-line. I filled the car with gas and as the tank was filling, I could smell fuel vapors from the area the arrow is pointing to. I replaced the hoses and both clamps that lead to the intake but the large leak code came back. I'm going to replace the other hose as well.

    To note, the only time there's ever a fuel smell is when there's gas being pumped into the tank and the vapor smell only comes from this specific location.

    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  22. #22
    Veteran Member Four Rings christianb5s4's Avatar
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    Alright everyone, so I've had the EVAP smoke tested and these two codes are really stumping myself and mechanics I've brought it to. Still gets the same P0455 and P0441 codes. Anyone have ideas? There are no bad ideas at this point. To recap I've done the following:

    - New OEM gas cap
    - Smoke test all lines
    - New purge valve and purge valve line w/ check valve
    - New leak detection pump
    - New charcoal canister
    - New fuel filter
    - All SAI and fuel lines inspected and leak free
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  23. #23
    Established Member Two Rings juniorcruzer's Avatar
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    were you able to confirm that the SAI line under the supercharger is leak free....that one would be impossible to inspect unless you took the supercharger off.
    2010 S4 3.0T, chipwerks stage I
    2010 A6 3.0T, APR Stage 2+, Roc Euro Intake, VMR V710 18x9.5 HyperSilver, 30% tint, A3 clear marker lights, LED Reverse lights, RS6 Grill

  24. #24
    Veteran Member Four Rings christianb5s4's Avatar
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    IIRC that line goes from the purge valve to a port under the supercharger and has a check valve built in? If so I had it replaced with a brand new line already, should be this line: https://www.ecstuning.com/b-genuine-...e/06e103207am/

    Spent a few hours at the shop where they traced every EVAP line and smoke tested all of them and no leaks. However, I've noticed this odd noise coming from what I believe is the HPFP for a while and think it's related. After a drive and the car is fully up to temperature then shutting it off, there's this periodic pressure relief sound from the HPFP for a little while until the motor cools off. Is it possible for the HPFP to have an internal leak?

    I took a video of it and have pressed my ear to it and pinpointed the sound which without doubt is coming from this region. It's very faint in the video but at 6-7 seconds you can hear it if you turn the volume up.



    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  25. #25
    Veteran Member Four Rings christianb5s4's Avatar
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    Another reason I believe it's the HPFP is because my 800 mile old oil has a distinct fuel smell to it. I'm ordering a new one since it seems easy enough to DIY.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  26. #26
    Veteran Member Four Rings christianb5s4's Avatar
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    Does anyone know the specific location of this solenoid valve?https://www.ecstuning.com/b-genuine-...ch/037906283c/

    Here's the diagram of our 3.0T motor and vacuum lines and shows this solenoid being the part #6 in this picture.

    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  27. #27
    Established Member Two Rings juniorcruzer's Avatar
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    which number 6? there are two on top, and one down in the middle?

    Jon
    2010 S4 3.0T, chipwerks stage I
    2010 A6 3.0T, APR Stage 2+, Roc Euro Intake, VMR V710 18x9.5 HyperSilver, 30% tint, A3 clear marker lights, LED Reverse lights, RS6 Grill

  28. #28
    Veteran Member Four Rings christianb5s4's Avatar
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    The one down in the middle specifically.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  29. #29
    Established Member Two Rings juniorcruzer's Avatar
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    I will try to get a look at my car today and see if I can follow it to where it goes. As much as I have been under the hood lately, it is not apparent to me where it is from the drawing.
    2010 S4 3.0T, chipwerks stage I
    2010 A6 3.0T, APR Stage 2+, Roc Euro Intake, VMR V710 18x9.5 HyperSilver, 30% tint, A3 clear marker lights, LED Reverse lights, RS6 Grill

  30. #30
    Veteran Member Four Rings christianb5s4's Avatar
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    Thankfully I can say this has been finally solved. I had the high pressure fuel pump replaced as there was some evidence it was leaking oil slightly and leaking internally. At the same time, all EVAP lines were double checked and verified there's not a single leak. So we went back to the basics, checking out stock Audi photos of the C6 3.0T engine bay and discovered the cause.

    The EVAP line that should connect to the purge valve was connected to the intake and the PCV line that should connect to the intake was connected to the purge valve. Doh. Whoever worked on the car prior to my ownership put them on the wrong way around. No codes at all, car runs and starts smoother, power is more linear, gas mileage is up and I filled the tank and had no issues starting after fill-up.
    Imola 2001 Stage 3 S4: 312K - 2.4sec FATs - Completely Refreshed/Built Motor - SRM K24s w/ Custom Turbosmart wastegates - Clutchmasters Stage 4 - Etspec - Cinesnow WG/Oil Lines - SRM V3 Intercoolers - AA built trans - 4:1 Diff - JHM Trio - 034 - H&R Coilovers - FCP - Bosch Motorsports - OZ Racing - SRM/SSAC exhaust - Tons of New OEM parts

    2009 C6.5 A6 3.0T Prestige - stock, daily driver

  31. #31
    Veteran Member Four Rings ichi d's Avatar
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    Quote Originally Posted by christianb5s4 View Post
    Thankfully I can say this has been finally solved. I had the high pressure fuel pump replaced as there was some evidence it was leaking oil slightly and leaking internally. At the same time, all EVAP lines were double checked and verified there's not a single leak. So we went back to the basics, checking out stock Audi photos of the C6 3.0T engine bay and discovered the cause.

    The EVAP line that should connect to the purge valve was connected to the intake and the PCV line that should connect to the intake was connected to the purge valve. Doh. Whoever worked on the car prior to my ownership put them on the wrong way around. No codes at all, car runs and starts smoother, power is more linear, gas mileage is up and I filled the tank and had no issues starting after fill-up.

    glad you figured it out. now tune it and enjoy this car!!
    C7 4.0T - EPL stage 1 ECU/TCU.

    Donated - C6.5 Apr Stage 2



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