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Fuel Pump Control Module Replacement (23-32)

Publication date: 2008-04-30
Reference number: 23-32

FUEL PUMP CONTROL MODULE REPLACEMENT

FUEL PUMP CONTROL MODULE REPLACEMENT

TECHNICAL SERVICE BULLETIN

Reference Number(s): 23-32, Date of Issue:  April 30, 2008
VOLVO: S60 (plastic tank) 2005-2006; S60 R-line 2004-2006; S80 2005-2006; V70 (plastic tank) 2005-2006; V70 (plastic tank) 2005-2006; V70 R-line 2004-2006; V70 R-line 2004-2006; V70XC / XC70 2005-2006
NOTE: If using a printed version of this TNN, first check for the latest online version.

Description

A new fuel pump control module (also referred to as Pump Electronic Module, or PEM) has been introduced as a spare part, which requires a new location if it is replaced. This TNN applies to vehicles manufactured up to the chassis number in the chart below. If the PEM needs to be replaced, install the PEM in the new location as per the Service method below.

Vehicles: 

MODEL YEAR, FACTORY CODE AND CHASSIS NO REFERENCE

Model Model Year Type Factory code(1) Chassis No
S60 (plastic tank) 2005-2006 384 2 -509560
S60 R-line 2004-2006 384 2 -509560
S80 2005-2006 184 1 -430120
V70 (plastic tank) 2005-2006 285 1 -541131
V70 (plastic tank) 2005-2006 285 2 -539327
V70 R-line 2004-2006 285 1 -541131
V70 R-line 2004-2006 285 2 -539327
V70XC / XC70 2005-2006 295 1 -214136
NOTE: S60/V70 cars with steel fuel tanks are not included in this method.
(1) Factory code is position #11 in the vehicle's VIN.

Parts:

PARTS

Description Quantity Part No.
PEM 1 30769225
Cable harness, 2004 S60R and V70R only 1 30798698
Cable harness, all other listed vehicles 1 30798596
Flange screw 1 985191
Flange screw 1 985055
Flange lock nut 1 985869
Washer 1 960143

Service

  1. Information on new location 
    NOTE: The pump electronic module (PEM) has a new location. The PEM has been moved from its previous located on the fuel tank, as illustrated. The new location is on the right rear edge of the spare wheel well.
    Fig 1: View Of Previous Location Of Pump Electronic Module
    G05609641Courtesy of VOLVO CARS OF NORTH AMERICA.
  2. Preparatory work 

    Removal of interior components 

    Ignition key in position 0.

    Open the trunk lid/tailgate

    Remove:

    • the cargo compartment mat/floor hatches
      • Fig 2: View Of Cargo Compartment
      G05609642Courtesy of VOLVO CARS OF NORTH AMERICA.
    • the rear seat cushion

    Fold forward the backseat's backrest.

    Remove the side cushion. See:

    • Removal, replacement and installation
    • Body and interior
    • Interior
    • Rear seat, passenger seat, seat
    • Upholstery, side cushion, replacing

    Remove the right part of the backrest

    Removing the child seat bracket:

    • Remove the bracket from the floor
    • Place the insulation to one side
      Fig 3: Identifying Child Seat Bracket
      G05609643Courtesy of VOLVO CARS OF NORTH AMERICA.
  3. Cable harness removal 

    Remove the right floor hatch over the fuel tank

    Remove:

    • the cable harness connector by the wheel housing/sill (arrow in photo)
    • the cable harness connector at the fuel pump
    • the cable from its mountings
      Fig 4: Locating Cable Harness Connector
      G05609644Courtesy of VOLVO CARS OF NORTH AMERICA.

    Cut the cable harness as illustrated. This makes the cable harness easier to remove from the vehicle. Remove the remaining part of the cable harness with connector.

    Fig 5: Cutting Cable Harness
    G05609645Courtesy of VOLVO CARS OF NORTH AMERICA.
  4. Removing the old PEM 

    Raise the vehicle. PEM is located at the fuel tank on the right side.

    Remove: 

    • the connector from the PEM
    • the PEM from the vehicle
    • the cable harness from its mountings
    • the cable harness from the vehicle

    Check that the fuel line sits in its clamps.

    Installation 

  5. Replacing the cable harness 

    Replace the rear cable harness with a new one according to the Parts chart on page 1.

    NOTE: The photos illustrate the two different types of terminals on the two harnesses. Ensure that the correct parts are used.
    Fig 6: Identifying Harness Terminals For Model Year 2004 S60R/V70R Only
    G05609646Courtesy of VOLVO CARS OF NORTH AMERICA.
    Fig 7: Identifying Harness Terminals For All Other Vehicles
    G05609647Courtesy of VOLVO CARS OF NORTH AMERICA.
  6. Cable harness installation 

    Connect the connectors at the sill and fuel pump.

    Position the cable harness in the sealing ring socket and in the mounting on the body (arrow in photo).

    Install the floor hatch. Tighten to 6 Nm (4.5 lb. ft.).

    Carefully check that the seal is in place when the hatch is installed.

    Fig 8: Locating Cable Harness
    G05609648Courtesy of VOLVO CARS OF NORTH AMERICA.
  7. New PEM installation 

    The new PEM is to be positioned on the rear part of the spare wheel well on the right side between the two stampings and below the bead of sealant, as shown in the photo.

    Fig 9: Locating New Pump Electronic Module
    G05609649Courtesy of VOLVO CARS OF NORTH AMERICA.

    Remove the backing tape from the self adhesive Velcro strap and install the PEM. Connect the cable's connector from the cable harness to the PEM.

  8. Finishing work 

    Reposition the insulating mat.

    Install: 

    • the child seat bracket to the floor.

      Use new screws:

      • 1 M10 tightened to 50 Nm (37 lb. ft.)
      • 1 M12 tightened to 80 Nm (60 lb. ft.).
    • the backrest. Use new screw:
      • 1 M10, tightened to 50 Nm (37 lb. ft.)
    • Side cushion
    • seat cushion
    • cargo compartment carpeting/floor hatches.

WARRANTY CLAIM INFORMATION

WARRANTY CLAIM INFORMATION

LABOR OP LABOR DESCRIPTION LABOR TIME
28911-2 fuel pump control module, relocate 0.9 hr.
Claims may be submitted under the new car warranty when there is a documented customer complaint using claim type: 01
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