No fuel pressure 2004 S60

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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u00jabv
Posts: 4
Joined: Sat Nov 17, 2018 6:56 am
Year and Model: 2004 S60
Location: Indiana

No fuel pressure 2004 S60

Post by u00jabv »

After nearly 300k miles, my S60 2.4L let me down for the first time in 14 years, cranks but no start. I don't hear the fuel pump run at key on and engine will run on carb cleaner. Removed rear seat and can measure 12V between blue and black wire at connector 54/36 briefly at key on and continuously during crank. This connector is beneath cover below rear seat and supplies the PEM. The yellow wire from B:47 at ECM shows no voltage or PWM signal and appears to be grounded. Is the yellow wire a speed control for the PEM? Is voltage level or PWM signal required at yellow wire for PEM to run the pump? I am too old to tackle replacing pump or PEM, but I want to determine if I need to have it towed to the Volvo dealer 60 miles away or if I can have local shop replace pump or PEM. Would rather not have local shop attempt to diagnose. Thanks

jimmy57
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Post by jimmy57 »

Is there voltage measured between blue and black at the connector on fuel pump cap? That would be output of PEM going to the main pump.

u00jabv
Posts: 4
Joined: Sat Nov 17, 2018 6:56 am
Year and Model: 2004 S60
Location: Indiana

Post by u00jabv »

I am not sure where I can access the fuel pump cap. Would it be from beneath the vehicle? Thanks

cn90
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Post by cn90 »

At 300K, I'd replace the fuel pump.

- Bosch fuel pump is about $160, search PN on the web.
Vendors: rmeuropean.com or FCPeuro.com etc.
Get the fuel lock ring tool for $18 on ebay. This makes the job easier.

- The PEM: get one on ebay for $45 or get it at junkyard. Very easy to replace.
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

u00jabv
Posts: 4
Joined: Sat Nov 17, 2018 6:56 am
Year and Model: 2004 S60
Location: Indiana

Post by u00jabv »

There are videos which show that the fuel pump is accessible through the opening beneath rear seat, but I apparently have the rare metal fuel tank and there is nothing underneath the covers.

cn90
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Post by cn90 »

This video is for models with metal gas tank...

2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

u00jabv
Posts: 4
Joined: Sat Nov 17, 2018 6:56 am
Year and Model: 2004 S60
Location: Indiana

Post by u00jabv »

I was able to jumper around the PEM module at the PEM connector and fuel pump ran. Found a used PEM module on ebay for $35 for later models with velcro intended for inside mounting. All good now. It appears that the yellow wire control signal will have 0V during crank and key on engine off, which was the unknown. Will replace the pump next summer as preventative. Thanks for the help.

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Post by abscate »

If you know where the low fuel light is on your car, replace that fuel pump next summer

If you don't, save your shekels

The waveforms and connections for the PEM are documented here and in the XC90 forum for an incident last fall, searchable under part number
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