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PSA: KAE Fuel Pump Relay

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

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
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bmdubya1198
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PSA: KAE Fuel Pump Relay

Post by bmdubya1198 » Wed Feb 14, 2018 5:50 pm

Just thought I'd post this on here rather than leaving a review on FCP or elsewhere. First off, I didn't buy this relay new. I got it from a car at the junkyard, and it looked (and still looks) brand new.
I ran this relay for probably a year, maybe 5k miles. This is what it looks like now. You can see where it burned out. Fortunately this failed in the driveway when the car wouldn't start one morning, and I carry a spare in the glovebox. I highly recommend keeping a spare in your car, this can save you a lot of time and aggravation worrying about a tow. Failures aren't uncommon. Just make sure you have a T25 bit or screwdriver in your car to remove the cover.

Anyway, the lesson here is buy genuine. I'm once again running my 20 year old, 183k-mile relay with no problems. And yes, I have a new (used but tested) spare.
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jtp
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Re: PSA: KAE Fuel Pump Relay

Post by jtp » Wed Feb 14, 2018 5:55 pm

Good to know thanks
99 V70R AWD
Almost 155K Miles
Breaking is how I know it’s working

98 S70NA (sold)
95 850 Turbo Wagon (RIP)

ecbsykes
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Re: PSA: KAE Fuel Pump Relay

Post by ecbsykes » Wed Feb 14, 2018 6:27 pm

+1

I've gone through 2 KAE fuel pump relays in the last 4 years. Original lasted 14 years. I, too, have learned my lesson.
2000 V70XC - 295,000 miles
Hilton Tune, 16T Turbo, Mototec 3" downpipe, Blue injectors, IPD Short Ram Filter, Snabb Intake Piping & RIP kit, do88 Intercooler, TME Dual Exhaust, HID Projectors, R Panels, do88 Silicone Hoses

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Re: PSA: KAE Fuel Pump Relay

Post by erikv11 » Wed Feb 14, 2018 6:41 pm

Great info, thanks for posting.

I bought a brand new OEM relay back in January. Not due to failure just as insurance. It was hard to swallow at $56 when I have like 5 spares in the garage, but the car is with my kid 3 hours away. I'd rather swapping in the glove box spare wasn't required.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 286k
'06 S60 R, 167k
'99 Camry V6 :shock: 125k
gone: '96 NA 850 210k, '98 NA V70 182k

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Re: PSA: KAE Fuel Pump Relay

Post by WhatAmIDoing » Wed Feb 14, 2018 8:36 pm

If a KAE relay is your spare, better have 2 spares. I went through 3 in one day (glad I bought from FCP). And that KAE is now on it's way out after little over a year.
'98 S70 T5M - 282,000+mi - forever a project
'99 S70 "AWD" - 220,000+mi - part out :cry:
Knows enough to be dangerous :wink:

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Re: PSA: KAE Fuel Pump Relay

Post by erikv11 » Wed Feb 14, 2018 11:12 pm

My spares are all old factory Volvo ones all still working, I'll take that over a new KAE any day.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 286k
'06 S60 R, 167k
'99 Camry V6 :shock: 125k
gone: '96 NA 850 210k, '98 NA V70 182k

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abscate

Re: PSA: KAE Fuel Pump Relay

Post by abscate » Thu Feb 15, 2018 4:21 am

I'm still on my original at 200k. I did take it out and dremelled the terminals which were showing signs of thermal damage. I wonder if that helps extend life? Has anyone done root failure analysis on a dead one?
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Re: PSA: KAE Fuel Pump Relay

Post by jreed » Thu Feb 15, 2018 5:07 am

This is the best thread on fuel pump relay failure causes that I know of: viewtopic.php?f=1&t=9681

Main causes (not necessarily in order):
Cracked solder joint between pin and board
Electrolytic capacitor failure
Diode burn out
1997 855 GLT (Light Pressure Turbo) still going strong. Previous: 1986 240 GL rusted out in '06, 1985 Saab 900T rusted out in '95, 1975 Saab 99 rusted out in '95, 1973 Saab 99 rusted out in '94

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abscate
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abscate

Re: PSA: KAE Fuel Pump Relay

Post by abscate » Thu Feb 15, 2018 5:19 am

jreed wrote:
Thu Feb 15, 2018 5:07 am
This is the best thread on fuel pump relay failure causes that I know of: viewtopic.php?f=1&t=9681

Main causes (not necessarily in order):
Cracked solder joint between pin and board
Electrolytic capacitor failure
Diode burn out

That's excellent. Added the part number to that thread for search, 9434225

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Re: PSA: KAE Fuel Pump Relay

Post by wizechatmgr » Thu Feb 15, 2018 6:30 am

Would highly suggest checking your other relays while you're in there folks. Keeping a generic 4 pin 50A relay in the glove compartment will make your life a LOT easier. You can use a generic relay for the fuel pump, but it will be pumping any time the car has power and is on if I remember correctly. Good in a jam, not necessarily good longer term.


I happen to keep one of these on me, as well as an older/intermittent fuel pump relay.
https://www.amazon.com/gp/product/B003C549SY/

Would suggest carrying a spare starter relay - though if you keep a 24" piece of wire in your car you won't need it to get home.
Wisdom requires knowledge as a prerequisite, but knowledge can be developed due to a lack of wisdom.
In order to learn how to fix something, you must first learn how to break it.
1999 V70 XC AWD - ~187k miles

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