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XC70 1999 Non-start

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70
This topic is in the MVS Volvo Repair Database » Volvo 940: new ball joints, sway bar, end links, bushings
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Donzilla
Posts: 24
Joined: 20 March 2011
Year and Model: XC70 1999
Location: Portland, Oregon

Re: XC70 1999 Non-start

Post by Donzilla »

Took the fuel filter out, and black gas poured out...ick! And it looks pretty clogged. My Wife remembered that she did run the tank pretty low before the last refuel, and the car has been run on 87 as well in the past (I've tried to put 89 or 92 in when we refuel, though).

However, key on, fuel pump relay jumpered or not, I don't get any fuel out of the feed line to the filter, and still don't hear the pump turning on. Next step: https://www.matthewsvolvosite.com/forums ... =1&t=14484

Thanks for all the help, folks!

Oh, I also broke the fuel line's boot on the way into the filter...It seemed a little worn, but tore right off even though I was trying to take it easy. So now I'll figure out how to replace that, too, to get the new fuel filter back in place. :-(
Silver 1999 XC70 AWD; Previously Silver 1991 240 Wagon (with horns)
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bw77
Posts: 149
Joined: 27 April 2009
Year and Model: 99 S70GLT
Location: Upstate NY

Post by bw77 »

You said you jumpered the fuel pump relay, but did you check for 12V on pin 15?
Did you check for 12V at the fuel pump, maybe you have bad wiring going back there.
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Donzilla
Posts: 24
Joined: 20 March 2011
Year and Model: XC70 1999
Location: Portland, Oregon

Post by Donzilla »

Yes to the 12V at the relay, I'm going to open up the fuel pump today and take a look (and get one ordered right away, just in case).
Silver 1999 XC70 AWD; Previously Silver 1991 240 Wagon (with horns)
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Donzilla
Posts: 24
Joined: 20 March 2011
Year and Model: XC70 1999
Location: Portland, Oregon

Post by Donzilla »

Well, I cut the access panel for the fuel pump no problem with a dremel... Although slags of molten metal flying everywhere did not seem like a particularly good idea next to the fuel tank... :lol:

Unfortunately the Volvo is parked at somewhat of an angle (where the tow truck left it) and the tank (was) totally full of fuel. As I removed the retaining ring, fuel started spilling everywhere, and running out underneath the splash guard. I collected as much as I could, and I guess I'll just let it sit and flush with water before I start it again!

As it happened, I had the perfect tool in my tool box to release the retaining clips on the quick releases — see the pictures below — extra points if you can tell me what it is!!!

Now, my only question is these wires going into the top of the fuel pump assembly with red sheathing. They go in with these white plastic connectors, but those don't seem to come off. I see that if I had dropped the fuel tank, I could probably take them out without disconnecting them at all, but the way it is now they are too restrictive for me to actually get the pump out (see pictures). If those white things are some kind of disconnect, my only reasonable option is to cut and then splice them back together when I re-install. Thoughts? Thanks again!

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Silver 1999 XC70 AWD; Previously Silver 1991 240 Wagon (with horns)
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Donzilla
Posts: 24
Joined: 20 March 2011
Year and Model: XC70 1999
Location: Portland, Oregon

Post by Donzilla »

Well, I got the new fuel pump installed, and still no gas when I turn the key on or try to start.

I tried running 12V to the old fuel pump, and it doesn't do anything...

I checked for 12V right at the installed new fuel pump, both jumpered and with the relay in, and there is no voltage there.

Not sure what's going on, guess I'll need to sleep on it and think about it. I found an 'inertia switch' for sale online and am wondering if that could be the culprit. That or the ETM?
Last edited by Donzilla on 02 Apr 2011, 22:37, edited 1 time in total.
Silver 1999 XC70 AWD; Previously Silver 1991 240 Wagon (with horns)
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Donzilla
Posts: 24
Joined: 20 March 2011
Year and Model: XC70 1999
Location: Portland, Oregon

Post by Donzilla »

Also, there was significant carbon/blackening on the float reader electronics. Before I took the pump out, the gauge was reading all the way full. Now it's reading just barely over empty (I didn't spill THAT much fuel). I took lots of pictures, especially of the blackened part and the fuel pump assembly.

Thanks for any input.
Silver 1999 XC70 AWD; Previously Silver 1991 240 Wagon (with horns)
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bw77
Posts: 149
Joined: 27 April 2009
Year and Model: 99 S70GLT
Location: Upstate NY

Post by bw77 »

How did you test the old fuel pump?

Have you tested the old fuel pump off the car, with known good 12 volt and
known good ground?
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Donzilla
Posts: 24
Joined: 20 March 2011
Year and Model: XC70 1999
Location: Portland, Oregon

Post by Donzilla »

Yes, I put power leads from a bench power supply at 12V on it...
Silver 1999 XC70 AWD; Previously Silver 1991 240 Wagon (with horns)
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Donzilla
Posts: 24
Joined: 20 March 2011
Year and Model: XC70 1999
Location: Portland, Oregon

Post by Donzilla »

Alright, well looking at the pump assembly in the light of day, I had put the ground lead onto one of the signal wires. (Hence the fuel tank level indicator problem.) Switched it, and the new pump turns on. Yay! Made a temporary repair to the fuel line to the filter with some old pieces of fuel line, heater hose, 'plastic weld', and a propane fitting and we're on the road. Whoo-hoo! I'll have to order the proper fuel line from the dealer, I can't find it listed for the '99s online anywhere, though the delivery hose for the newer models is here: http://www.swedishautoparts.com/XC70/vo ... parts.html and it seems like they have the best price on fuel pump relays ($32) of anywhere too. Thanks folks!
Silver 1999 XC70 AWD; Previously Silver 1991 240 Wagon (with horns)
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Donzilla
Posts: 24
Joined: 20 March 2011
Year and Model: XC70 1999
Location: Portland, Oregon

Post by Donzilla »

Prices from the dealer on new fuel lines:

pump to filter is $ 103.72
filter forward is $ 437.07

I guess I'm going to go with regular 5/16ths fuel line and hose clamps. Anybody have a good diagram of where it's got to go?

Thanks,
Don
Silver 1999 XC70 AWD; Previously Silver 1991 240 Wagon (with horns)
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