P0442 on Your 2024 Volvo S60
Code P0442 on your 2024 Volvo S60 means the engine management system detected a small leak in the evaporative emission control system during its self-test. This sealed network captures fuel vapors from the tank and routes them through a charcoal canister into the engine. A leak of roughly 0.020 inches was detected — too small to see but within the system's sensitive monitoring threshold.
Cause Analysis for the 2024 S60
On a low-mileage 2024 S60 built on the SPA platform, the suspect list centers on manufacturing factors:
- Gas cap seating issue (32%) — A cap not fully clicked into place or contaminated by debris. The most common trigger on new vehicles.
- Tank seal valve defect (28%) — Volvo's tank seal valve (vent valve) may have a factory unit with borderline seal performance that fails the system's overnight monitoring despite passing initial quality checks.
- Assembly connection gap (20%) — A vapor line fitting or clamp not fully engaged during production. The S60's sedan layout routes lines through tight underbody spaces.
- Purge valve imperfection (13%) — An internal seal defect in the purge valve allowing minor vapor bypass when closed.
- Software calibration (7%) — Engine management updates from Volvo may refine leak detection sensitivity.
T8 PHEV Note
If your S60 is the T8 Recharge plug-in hybrid, EVAP monitors run less frequently due to intermittent engine operation. Mention your T8 configuration to the service advisor.
What To Do
- Gas cap check — Remove, inspect, reseat firmly. Monitor for 2-3 drive cycles.
- Volvo dealer — This is a warranty repair. The dealer will use VIDA diagnostics and a smoke test to resolve the issue at no cost.
Cost Reference (Warranty-Covered)
- Gas cap: $25–$50
- Tank seal valve: $190–$360 installed
- EVAP line repair: $100–$250
- Purge valve: $180–$340 installed
Warranty
Your 2024 S60 is under Volvo's 4-year/50,000-mile bumper-to-bumper warranty, with EVAP components covered by the federal emissions warranty (8 years/80,000 miles). This repair is fully covered at no cost.