Fuel System - Installing Extra Fuel Pump Feed Cable
NO: 23-29DATE: 1-17-2008
MODEL: See chart below
M. YEAR: 2005-2007
SUBJECT:
Installing Extra Fuel Pump Feed Cable
REFERENCE:
VIDA, TNN 23-28
THIS TNN SUPERSEDES THE PREVIOUS VERSION DATED 8-23-2007. THE ENGINE CODE LIST HAS BEEN MODIFIED AND STEP 10 HAS BEEN CLARIFIED. PLEASE UPDATE YOUR FILES.
Note!
If using a printed version of this TNN, first check for the latest online version.
Description
Certain S60, S80, V70, XC70, and XC90 vehicles use a demand-controlled fuel system with a fuel pump control module (FP control module, or Pump Electronic Module [PEM]) and a fuel pump with two pump motors. The fuel system design was modified in production during the summer of 2006. Each motor within the pump was given its own fused electrical circuit.
If the fuel pump fuse is blown and it is determined that the fuel pump is defective, the additional circuit should be added for vehicles within the chassis range shown above. This TNN provides instructions for installing this circuit.
Note!
Always first check if there is a fuse in position 29 in the CEM, as the chassis ranges above may be approximate, depending on engine code.
Note!
This repair is not applicable to the following variants:
^ S80 T6 and XC90 T6 (engine code 91)
^ Model year 2004 S60R and V70R
^ S60 and V70 vehicles with steel fuel tanks
Material
Special Tool
Service
1. Read the rear control module (REM)
Step 1 applies to all cars excluding the XC90.
Read the control module's hardware number in accordance with VIDA:
Diagnostics
Network
REM hardware number.
If the REM responds with either part numbers 8676391 or 30728512, proceed to Step 2. If the REM does not respond with either of the part numbers 8676391 or 30728512, then it must be replaced according to VIDA:
Information
Repair
Removal, Replacement, and Installation
Cables and Fuses
REM, replacing
If REM is replaced, reload REM with software as per VIDA.
2. Perform REM upgrade
Note!
Step 2 applies to all cars whether REM is replaced in Step 1 or not.
Perform REM upgrade, P/N 30677030.
3. Access the cable harness
Access the cable harness between the rear control module (REM) and the right-hand inspection cover for the fuel tank. See VIDA for information. Depending on model, this will include removal of trunk floor, trunk side panels, plastic cover along inside bottom of trunk, and right rear seatback. Remove the inspection cover (at arrows in photo) over fuel pump connector.
4. Disassemble the connector
Remove the brown 32-pin connector on the rear control module (REM)
Cut the tie strap securing the wiring to the connector housing (red arrow in photo).
Using two small screwdrivers (see photo above), remove the housing from the connector block.
5. Install new cable at REM
Note!
The service cable, p/n 30773851, has identical metal terminals, but one terminal has a rubber seal. The end with the rubber seal goes to the fuel pump. The end without the seal is installed here:
Install the service cable (P/N 30773851), terminal without seal in position 25.
Reinstall the connector block into the housing, and resecure the cables to the connector using a new tie strap.
Reinstall the connector onto the REM.
6. Route New Cable
Open the cover on the cable duct (see photo in Step 3).
Route the new cable from the REM to the fuel pump inspection cover, along the existing cable harness. Secure the new cable with electrical insulating tape.
Note!
Both of these photos are taken from the interior of the vehicle, looking back toward the trunk area.
7. Install new cable at fuel pump
Remove the 12-pin connector on the fuel pump.
Remove the secondary catch on the connector (red piece in photo; remove by carefully prying upward with small screwdriver).
Remove the cover plug in position 1 on the connector.
Move the blue cable from position 8 to position 1, use tool 9512638.
Install the service cable terminal with seal in position 8.
Reinstall the secondary catch and reinstall the connector onto the fuel pump.
8. Access the CEM (Central Electronic Module)
Remove the soundproofing panel under driver's side dashboard, see VIDA for information.
Note!
It should not be necessary to remove CEM from its position. Access to the connector in the next step is easier if the small connector below it in the CEM is unplugged, and if the ODBII access plug is unscrewed from its mounting.
9. Disassemble the CEM connector
Remove the black 32-pin connector from the CEM.
Remove the tie strap and the housing from the connector. Follow the same procedure as shown in Step 4.
10. Move the cable at the CEM
Move the yellow/red cable from position 4 to position 23, use tool 9512638.
This photo shows the terminals in the connector block. The yellow/red cable was originally in position 4, which is the 4th position from the bottom in the left row. Position 23 is 7th from the bottom in the right row.
Reinstall the housing and use a new tie strap.
Reinstall the connector onto the CEM.
11. Install the fuse in the CEM
Install a new 7.5A fuse in position 29 in the GEM
12. Finishing steps
Reinstall all removed panels and seats, see VIDA for information.
Warranty Claim Information