2003 S60 2.4 non-turbo
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Ffairlane7
- Posts: 2
- Joined: 29 January 2022
- Year and Model: 2003 Volvo S60
- Location: Connecticut, US
- Has thanked: 1 time
2003 S60 2.4 non-turbo
So I am having trouble starting my 2003 S60 2.4L non-turbo. My #3 Fuse under the hood keeps blowing (Vacuum Pump/Bifuel DFCO fuse) this started about a month ago after i brought my car into a non-Volvo mechanic who originally said my PVC box was cracked, then said it wasn't and just replaced hoses coming off it. After that he said it wouldn't start again and replaced the Fuel Pump Control Module & said that it had a bad ground wire that he replaced. That is when the fuse started blowing about 10 days after repairs. Now sometimes the car will start and sometimes doesn't -- sometimes tries to start and blows fuse -- other times the fuse blows as I replace it before I even try to start it -- and last but not least sometimes does not blow the fuse and will start and will start and run a days then fuse blows again. Just banging my head trying to figure it out. Anyone have any ideas???
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br0dy519
- Posts: 743
- Joined: 17 December 2019
- Year and Model: 2004 XC70
- Location: Windsor, ON
- Has thanked: 123 times
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I'm hoping this is an easy solution for you, but unfortunately I think you may have two separate unrelated issues.
These vacuum pumps have a reputation of dying by an internal electrical short, which also causes the fuse to blow. I didn't even realize I was running a car without a vacuum pump for god know's how long. An easy way to test and isolate the vacuum pump as your issue: Replace the fuse, then remove the electrical connector feeding the vacuum pump switch (located on the air filter housing), and short that connector out (use a scrap piece of wire or paper clip) to feed 12Vdc to the pump. If you hear the pump spin, great. If nothing happens AND your fuse blows. You found your issue on that circuit causing the fuse to blow. I would disconnect the pump until you can source a new one (and probably replace the switch as well which is very prone to breaking when removing it).
The problem is, the above might have absolutely nothing to do with your no-start issue. Something striking about your post is the fact that the fuel pump control module (PEM as we call it) was replaced by a non-Volvo specialist. Check your invoice, did he use a Dorman part? We had someone else on the forum chasing a no-start issue for a year because he installed an aftermarket PEM. Find a good used genuine one from Erie Vovo.
Don't fret, hang out around here long enough and you'll be fine. You're in good hands!
These vacuum pumps have a reputation of dying by an internal electrical short, which also causes the fuse to blow. I didn't even realize I was running a car without a vacuum pump for god know's how long. An easy way to test and isolate the vacuum pump as your issue: Replace the fuse, then remove the electrical connector feeding the vacuum pump switch (located on the air filter housing), and short that connector out (use a scrap piece of wire or paper clip) to feed 12Vdc to the pump. If you hear the pump spin, great. If nothing happens AND your fuse blows. You found your issue on that circuit causing the fuse to blow. I would disconnect the pump until you can source a new one (and probably replace the switch as well which is very prone to breaking when removing it).
The problem is, the above might have absolutely nothing to do with your no-start issue. Something striking about your post is the fact that the fuel pump control module (PEM as we call it) was replaced by a non-Volvo specialist. Check your invoice, did he use a Dorman part? We had someone else on the forum chasing a no-start issue for a year because he installed an aftermarket PEM. Find a good used genuine one from Erie Vovo.
Don't fret, hang out around here long enough and you'll be fine. You're in good hands!
04s60 2.4
04xc70 2.5t
04xc70 2.5t
prwood wrote:I wish I had a permanent car repair area that was covered, had a level surface, lighting and fans, a workbench, and tool cabinets. You know,like a garage. Much of my time during the job is spent hauling things up and down the stairs to the basement or in and out of the storage shed, or running back downstairs when I realize I need something else,or taking a break from standing out in the sun,or using flashlights or work lamps when it gets dark.
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