2001 2.5TDI 103kW S80 doesn't start anymore with no check engine light and no RPM
 

Hi!

I have a 2001 Volvo S80 with 2.5TDI 103kW d5252t engine with the following problem:

A month ago, my car drove very well for about 300km, after I stopped the engine for about 15 minutes, it started fine and died after 2-3 seconds and didn't start again. At that moment when I put ignition on, it didn't light up check engine engine (as usually does) and when I tried to crank the engine, there was no RPM showing and did not start. My first thought was that the CPS has gone bad, I removed it, cleaned it and put it back on, but that did not changed a thing. I towed it home and after few hours I started cleaning connectors, after I cleaned the 3 PIN connector from the injection pump, I heard the relay working and the engine started again.

Now, I have the same issue but this time cleaning the connector did not resolved the issue.

I tried diagnosing it with an ThinkDiag4 and I noticed the following things:
A. With the 3 PIN connector connected to the pump I get no check engine light, no RPM when I try to crank the engine and my diagnosis couldn't communicate with the ECMB. With the 3 PIN connector disconnected from the pump I get a flashing engine light, RPM is showing and my diagnosis connected to the ECM

Until this point I did the following things (not in order):
1. Cleaned any visible connectors.
2. Cleaned and checked CPS.
3. Checked and fully charged the battery.
4. Changed the fuel Injection pump (I thought it the pump electronics has gone bad).
5. Checked the voltage of the 3 PIN connector and it fluctuates between 5 and 7 volts with ignition on.
6. Checked if I get fuel at the pump and I do.
​​​​​​7. Checked if i get fuel at the injectors and I didn't.