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2002 S60 fuel pump return line

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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wrgallant
Posts: 24
Joined: 13 May 2022
Year and Model: 2002 s60
Location: ipswich ma
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2002 S60 fuel pump return line

Post by wrgallant »

replacing the fuel pump on a 2002 S60 with a plastic tank. Found that the return line was broken off whatever it is supposed to be attached to. Dropped the tank and can't find anything that looks like an attachment point. Anyone know what the return line is supposed to attach to?
IMG_1709 (1).jpg
IMG_1709 (1).jpg (16.11 KiB) Viewed 477 times

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Krons
Posts: 1068
Joined: 9 January 2022
Year and Model: 08S60 05XC90 02S60
Location: Des Moines, IA
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Post by Krons »

Did parts diagram show anything?
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
05 S402.4i (RIP, timing belt failure)
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wrgallant
Posts: 24
Joined: 13 May 2022
Year and Model: 2002 s60
Location: ipswich ma
Been thanked: 2 times

Post by wrgallant »

Nothing in the diagram but I figured it out.
A previous owner replaced the fuel line from the pump to the filter. When they did, they eliminated the T back to the pump return port.
I added a T back to the return port and now have correct fuel pressure

ZekeDaFreak214
Posts: 1
Joined: 26 October 2025
Year and Model: 2007 s60 2.5
Location: West warwick

Post by ZekeDaFreak214 »

Hey man, I'm having a very similar problem and someone who worked on my car kinda set me back a lot and I'm playing catch-up. Was just curious if I was to show you a couple pics of possibly you could help me out?? Ty for your time!!

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