Hi,

I'm a new member and could use some help. I've searched the tech sections and not found what I'm looking for. Friday morning the S40 would not start for my wife. There had been no problems leading up to this. When I got home I tried it, and it was cranking nicely but not firing. I tried to start it for a total of at least a minute. The only recent problem it had was that I replaced the battery about a month ago.

I checked the two exposed plug wires with a timing light and they are getting current. I listened to the injectors with a stethoscope and could hear ticking from all four. I checked a few appropriate fuses and they seem fine. I switched the "Engine" relay with another identical one and saw no change in symptoms. I also tried the valet key to make sure it wasn't a transponder issue.

I then disconnected the fuel line here:


and got almost nothing out when cranking. Just dribbles.

I took out the fuel filter. Nothing comes out of either of these lines (when cranking or not cranking) :


I can easily blow air by mouth through the disconnected filter.

Is the fuel pump most likely? I can hear it whine for a few seconds when I turn the key to start it. From reading the other posts, it seems the fuel pressure regulator is the most common suspect, but that's up front, right? I don't think any fuel is getting up there.

Also, what is this thing?


It is located behind the driver's side rear wheel. It has lines running up towards the front of the fuel tank and one running up to the fuel filler cap.

Thanks in advance for any help.






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I would say fuel pump.

 

Thanks. I assume it's in the tank and accessed from the top. I couldn't see an access hole in the trunk. Any idea how hard a job it is to drop the tank and replace the pump?

 

You can access it from the trunk according to Volvo's system.
They say move the front seats as far foward as possible.
Fold the rear seat foward.
Pull the floor carpet foward.
Remove 4 screws and protective cover.
Then remove the ring and fuel pump after unplugging everything.
I haven't had to change one yet. But if the pump runs and nothing comes out then it must be bad unless the guage is wrong and it is out of gas.

 

Thanks! You just saved me about 6 hours.

 

Let me know how it goes.

 

Annoying. Once I had the cover off, I turned the key to see if I could hear the pump running, and heard gas spewing out into the catch pan, so I put the fuel filter back in and the car started.

I now suspect that there's an intermittent connection in the wiring to the fuel pump, but I decided to watch a movie with my wife tonight, so I'll try chasing it down tomorrow. I don't want to put it back together and end up with her getting stranded when it does it again.

 

Well, the car is now running great but I don't know if I fixed the root cause. Only time will tell.

I dissected the electrical cable for about 6" back of the fuel pump connector, found no problems, couldn't generate an intermittent by wiggling it, so I buttoned it back up with an extra couple of layers of friction tape. I cleaned the contacts on both male and female sides with contact cleaner, added electrical grease and reassembled. Thanks for your help.

In case anyone would like to see it, here are a few pictures of the fuel pump access:






I didn't actually get to change the fuel filter as the AutoZone one would not fit, so I returned it. It had the correct fittings, but it was too long so it would not fit the clamp, and the fuel lines did not like stretching to fit onto it.


Also, the plastic clamp holding the filter too the tank was made of a really brittle plastic. I broke it removing it. Lots.

I wanted to replace it with a stainless hose clamp, but decided that since Volvo saw fit to put a grounding point on there I probably ought to too. I am not the Human Torch. It was a bit of work to mod a hose clamp this way but it should last.

Here is my clamp next to the OEM:


and installed:



Andy

 

That thing by the LR wheel is the evaporative system leak detection pump. It pressurizes the fuel evap. system to check for leaks.

Nice handi-work on the ground strap.