2005 S60 No Fuel Pressure

[ceason]

Hi Guys
I'm looking for ideas.

Here is my saga

Leaving work several weeks ago my Volvo stumbled and died. I had it towed home and spent the weekend troubleshooting. The car was not getting any fuel at the rail and I never heard the fuel pump come on. I checked the fuel pressure sensor and it seemed to work fine. I ran the fuel pump from the battery and it would run and generate pressure at the rail. So I decided the PEM must be bad and ordered a new one. Opening up the old PEM I could see the FET and diode was damaged.

Swapped out the PEM and the car started right up, but now the ABS light was on, engine light was on, and power steering was disabled. Also the immobilizer light would illuminate the first time I attempted a start and the second time it would start and was drivable. I took it to a Volvo only repair shop in town and they pulled a couple pages of error codes and reset the computer. But the lights came back on. They said they never saw this before and I would need to leave it with them for a week for them to check it out.

Not willing to pay $100 an hour for someone to attempt to troubleshoot it I decided there must be something wrong with CEM and sent it off to xemodex to be repaired. When computer came back the car would start and run for 2 seconds and die... even worse than before. I've been attempting to work with Xemodex but they seem to have almost zero support. They asked me to disconnect the BCM but it did not help. I ordered Dice Vida and I'm hoping that provides some clues.

Currently when I reconnect the battery I will here one motor of the fuel pump running. Then I when I put the key in I will get the second fuel pump motor (high pressure) for about 10seconds. Car will start then die right after. I do not hear the high pressure motor kick back in and when I check the fuel rail and there is no pressure.

I would appreciate any ideas. I will post pics of the damaged PEM and also the error codes tonight.

Also this is the T5 model.

[JDS60R]

I'm going to ask a few questions that might help others give you guidance. I've attached some materials for reference.

Could you please share what engine/trans combo you have?

I am not aware of a 2005 S60 with 2 fuel pumps or a dual stage motor.
" Currently when I reconnect the battery I will here one motor of the fuel pump running. Then I when I put the key in I will get the second motor for about 10 seconds"

I think a fuel pressure gauge may help so you can diagnose the actual pressure provided. You may just have a failing fuel pump - but as always you should find evidence of it not meeting its performance spec before considering replacement.

How did the power steering disable itself. Is the belt on? Is it a variable assist ( solenoids on rack) ?

[ceason]

Attached is the wiring diagram showing two motors in the fuel pump.

Volvo can electronically disable the power steering

[ceason]

2005 S60 T5 the motor is 2.4L 5cyl Turbo

[ceason]

Attached it the original PEM. You can see the damaged FET and diode.

Good news is I received the Volvo Vida DICE today. Hopefully it works and I can pull the codes tonight.

[JDS60R]

Please add the T5 to your sig . I thought you were in a NA as your sig said 2005 S60.

Volvo can only alter the pressure ,at the rack, with the "speed related steering" option so you must have that one.

Let us know the codes and the fuel pressure readings?

I've changed a few of those pumps - I never took one apart. I'll ask an expert friend on if its a variant I haven't seen. I thought they were all pulse width modulated ( DECOS) on a single pump for fuel pressure. (not counting any transfer pumps/valves).

[JDS60R]

Ok - so here is the answer.
The schematic shows the dotted lines for a variant wiring. ( I thought it might be some 2 pump variant I had never seen). I confirmed with a Volvo expert that they only have one fuel pump for the fuel injection delivery.

Let us know what the codes and fuel pressure are. After all - it doesn't matter how many pumps it has as long as you are getting the pressure and flow you need.

I hope you are up and running soon. I'll can help troubleshoot if needed after you post the codes/pressures.

[jimmy57]

Check current draw of the main pump that the PEM controls. My thought is the pump killed the PEM and the new PEM is shutting down from overcurrent. normal would be 8A or less and PEM may not tolerate more than 11-12A
A T5 in that year range is very likely to have Servotronic steering and they can go to greatly reduced assist but there will still be a huge diff between engine off no assist and engine running reduced assist.
IF you disconnected battery the ABS lamp may be on until you drive the car past its test speed the first time.
Fuse 16 on CEM is for the steering assist regulation and it may not be intact or was not put back.

[precopster]

The current measurement can be performed at the fuse by placing it in series with a meter or by looking for the sender/power junction point under one of the rear seats under the steel hatch.

On 2002 there are 4 light guage wires (for senders) and 2 heavier guage wires for fuel pump power. (Six wires in total)

By breaking the green lead (pump 12V+) and measuring current flow through this you should read no more than 4A at pump prime. If the PEM has shut down due to failure or over current protection you may be advised to introduce your own 12V+ supply to the 2 heavier guage wires (while PEM is out of circuit by cutting them) in order to assess the pump's health.

Once you do this you should have some squirt at the rail.

[jimmy57]

I check them at the PEM on ones with PEM.
Unplug PEM and jumper 3 to 5 and use ammeter between 2 and 4.
This gets main pump and LH supply pump for ejector pump is not affected and is not in circuit.
On PEM cars the fuse will get both pumps and the PEM will be regulating the main pump and you won't get its full current draw.