Help! 04 S60 will not start, no fuel pressure METAL TANK

smokedlights · Post by **smokedlights** » 02 Feb 2026, 19:45

Have spent so much time on going in circles with this thing so here are the facts:
Would not start out of the blue one day, cranks and cranks
Replaced fuel pressure sensor, replaced fuel pump, replaced fuel pump module 2x.. I still believe its the fuel pump module because:
When I crank the car I get power going to the module.. I get NO fuel pump running. I can manually hook up 12v to the pump wires on the module plug and the car will start. I have hours of researching and see nothing that says plastic tank vs metal tank has any different module? My exact part number seems very difficult to find 8634953 (there is ONE on ebay with my part number that im going to try. I have tried 2 other fuel pump modules prior with same results. I cant wrap my head around anything except the module, unless im missing something here?? Car also has "Vin 64" which im discovering is rare as well

Post by **erikv11** » 02 Feb 2026, 21:10

Are you sure all the wiring is good back there around the module and the pump?

Post by **cn90** » 02 Feb 2026, 21:46

Metal tank: the PEM usually sits on top of the metal tank.
I posted some photos and tricks in forum.

Virtually all the PEMs for P2 cars are the same, I also posted the info in forum.

smokedlights · Post by **smokedlights** » 03 Feb 2026, 09:09

erikv11 wrote: ↑02 Feb 2026, 21:10 Are you sure all the wiring is good back there around the module and the pump?

yep.. has to be if I tested 12v to the module. and then put 12v to the pump itself and car starts. Power seems to be going into module, but not coming out of it to power the fuel pump

smokedlights · Post by **smokedlights** » 03 Feb 2026, 09:10

cn90 wrote: ↑02 Feb 2026, 21:46 Metal tank: the PEM usually sits on top of the metal tank.
I posted some photos and tricks in forum.

Virtually all the PEMs for P2 cars are the same, I also posted the info in forum.

well aware of where its at, as ive changed it twice now as mentioned.. Power to the module... no power coming out im leaning towards "virtually all" is not "certainly all" Wouldnt blow my mind since its a completely different fuel pump as well with metal tanks.

What also gives me a clue is that FCP euro, only carries two of the fuel pump modules and lists them as " For metal tank" seems they would classify them for a reason.. wheres the volvo gurus??

Post by **cn90** » 03 Feb 2026, 11:07

Re Volvo 8634953...they are all the same PEMs.
I have played with all these PEMs with different Volvos.
They work out to be the same.

I suggest that you check the wiring from PEM ---> Fuel Pump.
Sometimes it is pinched.

smokedlights · Post by **smokedlights** » 03 Feb 2026, 13:12

cn90 wrote: ↑03 Feb 2026, 11:07 Re Volvo 8634953...they are all the same PEMs.
I have played with all these PEMs with different Volvos.
They work out to be the same.

I suggest that you check the wiring from PEM ---> Fuel Pump.
Sometimes it is pinched.

I def will today at first glance everything seemed fine but will get more in depth... literally was running fine one day and the next day it wouldnt start. I could def see mice or something if it wasnt winter and sat for an extended time. Still has me mind boggled tough because I literally powered the fuel pump from the PEM plug itself.. started car and ran , instant fuel pressure. Perhaps the actual ground to the PEM or something

Post by **jonesg** » 04 Feb 2026, 03:35

its advisable to order the PEM adapter harness from FCP and relocate the PEM to the spare tire area.
Grab another used PEM on ebay.

smokedlights · Post by **smokedlights** » 04 Feb 2026, 08:43

jonesg wrote: ↑04 Feb 2026, 03:35 its advisable to order the PEM adapter harness from FCP and relocate the PEM to the spare tire area.
Grab another used PEM on ebay.

car has 220k miles.. dont care about relocation just need to get it started.. ordered 2 pem from ebay one new one used.. neither made it start.. only time it starts if it i put a battery to the fuel pump via the PEM plug..

Post by **jonesg** » 05 Feb 2026, 21:07

smokedlights wrote: ↑04 Feb 2026, 08:43
jonesg wrote: ↑04 Feb 2026, 03:35 its advisable to order the PEM adapter harness from FCP and relocate the PEM to the spare tire area.
Grab another used PEM on ebay.
car has 220k miles.. dont care about relocation just need to get it started.. ordered 2 pem from ebay one new one used.. neither made it start.. only time it starts if it i put a battery to the fuel pump via the PEM plug..

next step would be to test wiring continuity at pem to the plug at the pump.
Pem should see continuous 12v feed, its ground side switched via CEM?
You'd have to look at the circuit diagram to trace the signal wire.

You didn't give enough information to track the wiring diagram but you can do it easy enough, its all here.
https://charm.li/Volvo/2004/