Re-upping previous post- XC90 No start

powersct · Post by **powersct** » 02 Mar 2011, 19:33

Service Bulletin NO: 23-29 DATE: 1-17-2008 MODEL: See chart below M. YEAR: 2005-2007 SUBJECT: Installing Extra Fuel Pump Feed Cable REFERENCE: VIDA, TNN 23-28 THIS TNN SUPERSEDES THE PREVIOUS VERSION DATED 8-23-2007. THE ENGINE CODE LIST HAS BEEN MODIFIED AND STEP 10 HAS BEEN CLARIFIED. PLEASE UPDATE YOUR FILES. Note! If using a printed version of this TNN, first check for the latest online version. Description Certain S60, S80, V70, XC70, and XC90 vehicles use a demand-controlled fuel system with a fuel pump control module (FP control module, or Pump Electronic Module [PEM]) and a fuel pump with two pump motors. The fuel system design was modified in production during the summer of 2006. Each motor within the pump was given its own fused electrical circuit. If the fuel pump fuse is blown and it is determined that the fuel pump is defective, the additional circuit should be added for vehicles within the chassis range shown above. This TNN provides instructions for installing this circuit. Note! Always first check if there is a fuse in position 29 in the CEM, as the chassis ranges above may be approximate, depending on engine code. Note! This repair is not applicable to the following variants: ^ S80 T6 and XC90 T6 (engine code 91) ^ Model year 2004 S60R and V70R ^ S60 and V70 vehicles with steel fuel tanks.

This is huge info on this problem. Turns out the fix from Volvo is to remount the PEM inside the car and run a new circuit for the second pump. Should sticky this somewhere. I will have the actual instructions soon and will post a link.

powersct · Post by **powersct** » 05 Mar 2011, 13:24

The final outcome- Module arrived ($285) plugged it in and car started right up.

The owner decided not to run it inside as called for by Volvo in favor of moving it on.

I am still planning to post the TSB and instructions from Volvo- right after I get it all back together tomorrow.

Post by **jimmy57** » 05 Mar 2011, 13:28

originally the modules are outside for cooling but corrosion issues forced the move to an internal location.
The module gets hot and when splashed with water cools and a suction will pull the moisture in if its on the connector.

I had forgotten that the XC90 V8 was one of the ones the TSB applied to.

powersct · Post by **powersct** » 05 Mar 2011, 13:55

Not only that, but I noticed a redesign of the module as well. The old one had an exposed copper connector right above the plug with a small hole as well. The new one is completely sealed and the copper connector is not exposed. As the owner opted not to run it inside, I'm going to seal the connector with some spray ignition sealer that I have handy for my old Range Rover- it works very well for these sort of issues. Thanks for your help Jimmy.

ndiggy · Post by **ndiggy** » 27 Sep 2011, 09:46

I'm having problems with the PEM on my 2005 S40 and I'm hoping to replace the part myself. Due to some other complications with the electronics in my car, the repair isn't going to be covered under the warrenty.

Powersct you said you had instructions on replacing the module? Would you be able to post the them?

powersct · Post by **powersct** » 27 Sep 2011, 10:05

Hmmm. This was awhile back now, but I will take a look for them. This was a wagon (XC90) and the module was in the front of the right wheel well well behind the liner. As I recall, the fix was to move it inside the car and re-route the wiring. The owner decided not to go that route and I just replaced it- plug and play...

volvodoc · Post by **volvodoc** » 28 Sep 2011, 08:52

fuel pump module is located in r/r inner fender well common problem they get water in them and short be advised if this is your problem there is a relocation kit to move them inside also it is common to blow the fuse under the hood when this happens

powersct · Post by **powersct** » 28 Sep 2011, 08:59

Just another point on this- the old module had a small hole/opening where you could see part of a copper connector on the front- the new replacement was fully sealed. Presumably this is where water would enter the old one. The copper was corroded as well.

volvodoc · Post by **volvodoc** » 28 Sep 2011, 11:31

can you explain the pem should be a sealed unit are you sure your looking at the right part

powersct · Post by **powersct** » 28 Sep 2011, 11:54

I am talking about the module as you describe in the RR wheel well (black box approx 4x6 with the connector on the bottom). Going from memory here on the XC I was working on, but I clearly remember the new unit not having the opening which was small but clearly there on the old one right above the connector on the front of it.

Re-upping previous post- XC90 No start

Re: Re-upping previous post- XC90 No start