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Discussion Starter · #1 ·
First day on Swedespeed so please forgive any of my mistakes.

I have a 2004 Volvo S60 2.5T with about 80k miles.

The other night the car stalled on me. Took it to the dealership and they said that the fuel pressure sensor and the fuel pump control module are bad. And needed $1300 to replace both.

I took it to an independent who came to the same conclusion after diagnostics, but he said that he has never seen a fuel pump control module go bad. He has been in business for 30+ years.

I called IPD and they have never seen a fuel pump control module go bad. So now I am looking for information this fuel pump control module. How difficult is it to replace? Where can I find replacement procedures? I can't find anything in VADIS on replacement steps.

Is there something that could be causing the failure that is more likely of a culprit?

Thanks.
 

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pem should only be on late 2004 and 2005 and up cars. very easy to replace it is attached to the gas tank next to the fuel filter on the 04, 05 and up its in the trunk. just held on by clips. they dont know what they are talking about they go bad all the time volvo even has a recall on the pem on the s40/v50 cars
 

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Discussion Starter · #3 ·
Thank you for the information.

I have a few follow up questions if you don't mind.
What does PEM stand for?
Do I need to drop the gas tank to replace or is it reachable from beneath the vehicle?
 

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PEM fuel (pump eletronic module) no need to drop the tank its on a plastic bracket on the side of the tank next to the fuel filter on late 04s. are you sure it has been diag right, there is a recall on the fuel rail sensor so that should be free and it could be the fuel pump that is faulty. is there any codes for the pump module???
 

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Discussion Starter · #5 ·
The mechanic showed me the diagnostic results from VADIS that showed the pump module was bad. Duty cycle is supposed to be approx. 35% and mine is at .14%. I had a failure at both the fuel pressure sensor and at the control module. Unfortunately my pressure is outside of the recall range.

I believe the diagnostic code for the pump module is 2120. I am new to all of this so I apologize if this doesn't make sense.....first time user of VADIS.
 

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2005 VOLVO S40 RECALL - #08V033000
ON CERTAIN VEHICLES SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA, REOCCURRING, LONG-TERM EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS SUCH AS SALTY-WET CONDITIONS, IT IS POSSIBLE FOR THE PUMP ELECTRONIC MODULE (PEM) TO BECOME CORRODED INTERNALLY. THIS CAN CAUSE A FAULTY SIGNAL TO THE FUEL PUMP, RESULTING IN LOW OR NO FUEL PRESSURE TO THE ENGINE.

Why not recall S60 for this problem? I just replaced mine last week!!!
 
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Hi friends,
The dealer says I need a new PEM fuel module for my 2005-XC70. Can anyone tell me where this is located? I've heard different stories, ( under the wheel well, on top on the gas tank, beside the gas tank, under the seats, etc.) Anyone know the straight goods on a 2005 XC70??
Thanks
 

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Greetings from Maui Hawaii
I have 2009 Xc70 T6 and having starting issues on occasion. Reading my Bluedriver when this issue happens my fuel pressure is at 30 or 32 psi & when its running strong about 58 PSI.

I have been searching for info on locating the Fuel Pump Control Module on my wagon. Any ideas & help would be greatly apprenticed. Is this the answer to my starting issue OR is the fuel pump in the tank the problem?
Replacing the PEM seems allot easier & from the forum posts I have read probably more of the issue.

Thank you so much.
Tad
 

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i would replace the rail sensor first and see what changes
What he said ^. If that doesn't fix it, source a good used PEM. Especially from a junk yard in a SW state where there is no salt on the roads in winter. It isn't a hard job and there is no programming required.
 

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Greetings from Maui Hawaii
I have 2009 Xc70 T6 and having starting issues on occasion. Reading my Bluedriver when this issue happens my fuel pressure is at 30 or 32 psi & when its running strong about 58 PSI.

I have been searching for info on locating the Fuel Pump Control Module on my wagon. Any ideas & help would be greatly apprenticed. Is this the answer to my starting issue OR is the fuel pump in the tank the problem?
Replacing the PEM seems allot easier & from the forum posts I have read probably more of the issue.

Thank you so much.
Tad


UPDATE 03-05-20
So I found the PEM on my car. What a hassle. After looking in TEN different spots I jacked up the car, undid the metal protective plates. I Put a hydrolic jack with a board under Driver side & undid TWO large bolts dropping gas tank 5 inches. Was just enough for me to get my hands on PEM & take a picture with cellphone of label. Ordering a new PEM tomorrow.
 

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not starting ....sometimes

Hello, new here but i have a 2008 xc70 and i have been having issues that i can't seem to get resolved.

had my car do something weird when i pushed her pretty hard to get into traffic. A weird WHOOSH sound and it ran until i got off the highway and pulled into a parking lot where it shut down. After trying for several minuets to get it running i got it to run enough to get to a parking spot. I removed the battery cable and gave it a couple of minuets, reconnected it and it started right up and got me home.

I next rented a code reader and it had a fuel rail pressure sensor fault. I replaced that and it kept throwing the 2 lean bank codes. I took it to a mechanic and he replaced the PCV box (oil separator) that had a torn diaphragm. I thought i was good to go but......................70 miles and a potty break later check engine light is back on. Same lean bank codes (Po171 P0174) Took it back to the mechanic and he changed the battery, and did a smoke test and found a couple small air leaks replaced a couple of o rings to fix the air leaks, and same thing. The care drives fine runs good but when i start it every day or 2 or 3 it will not want to start and idle and will die several times until i can get the rpm's up to 3000 or so then it will start to run and i can drive it and it will clear up and run good. one other thing my gas gauge is now acting up. I "broke down" and my fuel gauge showed over 1/4 of a tank. i put gas in it and it started right up.

I have done some research and am leaning towards the fuel control unit. Thoughts???? how is this confirmed/diagnosed Do i get to it from the bottom or from the top? they are $300 What are the thoughts of getting a used one from ebay or such?? Thanks for any help.
 

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not starting ....sometimes

I have done some research and am leaning towards the fuel control unit. Thoughts???? how is this confirmed/diagnosed Do i get to it from the bottom or from the top? they are $300 What are the thoughts of getting a used one from ebay or such?? Thanks for any help.
An old post here, but just wanted to add my 2 cents for the next poor fella looking for stall/no-start answers...

My 2005 XC70 died on my way home the other day and had to get it towed. After some research I isolated the problem to the fuel pump control module / fuel sending unit / PEM. My computer reader pointed to that as well. A super EASY fix btw on my 05 XC70.

Within the last few years I've replaced the spark plugs, ignition coils, fuel filter, fuel pressure sensor, and alternator, so I could safely rule all that out. There was also little pressure at the schrader valve on the fuel rail--I don't have a fuel pressure gauge, but when depressing the schrader valve zero gas came out (use a rag and safety glasses btw when doing this just in case there’s still lots of fuel pressure in the line).

The car turned over strong, but no start. Battery, alternator, plugs, coils etc. all good. Had to be fuel related.

I found the PEM new on FCP Euro for $400 and almost bought one, but decided to head to the local Pull 'n Save as their website said they had a bunch of volvos. From what I understood Volvo used pretty much the same exact PEM in their cars from 2001-2011 even though they all had different numbers on them, so I dug through a few different volvos. Luckily I found a PEM mounted in the trunk of a V70 that was pristine, unlike my PEM which was mounted under the car exposed to all the elements (New England salt in my case). I also read somewhere that Volvo changed the design from my 2005 car so they weren't exposed anymore.

So my junkyard PEM was a whopping $33. She fired right up after plugging the used unit in. Took the car for a 250 mile road trip shortly after replacing the PEM with no issues. Unlike what Volvo will tell you this part does NOT need to be programmed. It is completely plug n play. Attached here are photos of the new and old unit. The one made in Spain is the original; the one made in Germany is the junkyard find. Apparently they were manufactured all over the place. As of this writing Ebay has a bunch of used units for around $40-50 too.

On my 2005 XC70, the PEM is easily accessible mounted under the car, next to the fuel filter, by the right rear passenger side wheel. There's 4 clips you need to pry outwards at the same time which is tricky but you can just wedge 4 flat screw drivers etc up there one at a time and on the last one the unit pops right off, downwards. Depending on the year and model, this PEM can be in a bunch of different places such as under the rear seats, in the trunk area near spare/3rd row seat, or on top or side of the fuel tank, to name a few.

Note, if you have an exposed PEM like me and you end up buying a used replacement, which I highly recommend, make sure to fill around the edge of the metal heat sink where it meets the plastic, on top, with JB weld or super tough calk or something to keep water out. My old PEM was in fact sealed this way and still eventually failed, but the replacement I got at the junkyard was not sealed becuase it came from inside another car/model/year. Seal it good otherwise it will just fail again fast.
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