A couple of months ago, the Check Engine Light (CEL) came on on my 2006 Volvo S60. I had Volvo check the codes and the problem was with the Fuel Pump Regulator. So I replaced the fuel pump.

After a couple of days, the CEL came back on. I took the car back to Volvo, they said I had about 2-3 cups of debris in the fuel tank and recommend a complete fuel tank replacement. They refused to give me the codes. Thinking they were nuts so I changed the fuel filter. But that did not fix the problem. The battery was almost bad, so I replaced the battery. That did not fix the CEL. I replaced the O2 Sensor, that did not fix the CEL. I replaced the Fuel Pressure Sensor, that did not fix the CEL.

The other day, my fuel tank was down below 1 gallon of gas and the CEL went out. I put 3 gallons of gas in and the CEL came back on. The fuel tank is down to below 1 gallon again and the CEL went off. I opened up the tank, but I cannot reach the front end of the fuel tank. Could debris be causing this problem? If so, how do I suck the debris out?

 

You need the codes otherwise it's just guessing. If the light is on (or was on), there are codes.

 

I finally was able to get the codes from Volvo. They originally refused to give them to me. Below are the codes. Volvo service says the problem is there is 2-3 cups of debris in the gas tank. When I checked, I could not find any debris and Volvo service told me that the gas tank has layers to to push debris away from the fuel pump. This does not make any sense to me since the fuel pump has a debris/sediment filter on the end to prevent this and the filet is completely clean.

Control Module - Diagnostic Trouble Code | Status
AUM | No fault found.
BCM-O103 Pedal position sensor Faulty signal | DTC is found not active.
CCM-0062 Damper motor, temperature left Internal fault | DTC is found not active.
CEM | No fault found.
DDM | No fault found.
DIM | No fault found.
ECM-2900 Fuel pressure - Faulty signal | DTC is found active.
ECM-900C Brake pedal sensor - Signal too high | DTC is found active.
PDM | No fault found.
PSM | No fault found.
REM | No fault found.
SRS | No fault found.
TCM | No fault found.

 

If there is crap in the tank, it could be the cause. Otherwise, I'd try a fuel pressure sensor. Pretty common.

 

Sorry but I can't figure out how you got "debris" in the tank or why you would run a tank down to the last gallon.


It appears that you need a new fuel tank.
Look for an auto recycler...

 

It's easy to get debris in there if he wasn't careful when replacing the pump. I don't think that's his problem though, unless there really is there cups of debris as claimed.

 

Am I missing something? Maybe it is the wordage "I replaced" multiple items, or should it be "I had them replaced."

Seems if OP was able to replace all the items he/she said, they would obviously be able to get codes without dealer being involved.

 

You said my thought better

 

I also think that a salvage tank might be better for cost than a "NEW"

 

Thank you for all of the replies. When I mentioned "I replaced", I did replace all of the parts listed above. The reason I mentioned the 1 gallon of gas is because I was thinking there was a problem the vacuum in the gas tank???.

 

Plus I am not sure how Volvo Service was able to determine how much debris was in the gas tank. Can someone explain is the purpose for the fuel pump's filter if debris in the gas tank can cause problems?

 

Sorry, I forgot you replaced the sensor. It had been a while and I didn't re-read your original post.

You need to know the fuel pump duty cycle, which requires VIDA.

If the screen gets clogged, it will set that code because duty cycle will be high.

 

If there were issue with regulator why you've replaced the pump itself?

 

There is no regulator

 

I mean Pump Control Module.

 

I have a (plumbing) inspection LCD camera ($150) with a 5 foot reach that I have had for years.
You can buy one at Harbor Freight for about $90. Not sure about what it is.


Newer tech and color are listed in the ad.
Mine is B/W and has a bright light.


It should be able to see into the tank and "estimate" the volume of debris and gas remaining.
???