NHTSA ID Number: 10057900
Manufacturer Communication Number: TJ25477
TSB/Document Date: 2015-07-10
Summary
VOLVO
2004-2010 : PUMP ELECTRONIC MODULES HAVE NO ERRORS. TO PREVENT FAULTY ERRORS REPLACE & PREVENT REPAIR PROCEDURES. *LJ
SB-10057900-6665
VOLVO CARS
SERVICE AND PARTS BUSINESS
Technical Journal
TITLE:
Improved fault tracing for fuel distribution system (PEM)
REF NO:
ISSUING DEPARTMENT:
CAR MARKET:
TJ 25477
Technical Service
United States and Canada
PARTNER:
ISSUE DATE:
3 US 7510 Volvo Cars North America
FUNC GROUP:
2340
FUNC DESC:
YEAR
MONTH
DAY
2015
04
14
Fuel tank, fuel lines, evaporator
system
Page 1 of 4
“Right first time in Time”
Attachment
Vehicle Type
Type
Eng
5XX
5XX
5XX
5XX
38
39
67
68
Eng
Desc
Sales
Body
Gear
Steer
Model Year
2004-2010
2005-2010
2008-9999
2004-2008
Plant
Chassis range
0000295-0514413
0000295-0514301
0000295-9999999
0000295-0058153
Struc Week
Range
200338-201019
200420-201019
200720-999952
200339-200819
CSC Customer Symptom Codes
Code
1Q
AJ
AK
AL
AM
BB
AP
7A
AA
AB
BJ
DL
Description
Driving/Poor performance/lacks power/At take off
Driving/Poor performance/lacks power
Driving/Hesitates/surges/Unsure when/at all times
Driving/Hesitates/surges/During acceleration
Driving/Hesitates/surges/During deceleration
Driving/Engine stalls/Unsure when/at all times
Idling/Engine stalls/Unsure when/at all times
Starting/Engine stalls
Starting/Engine does not start/Engine turns
Starting/Engine hard to start/cranks slowly/Unsure when/at all times
Starting/Engine does not start/Unsure when/at all times
Warning lights and chimes/Malfunction Indicator Light ("Check engine" light) indication/no indication
Produced in the USA and available as an electronic document. Hard copy documents are printed in USA on recycled paper containing
a minimum of 50% wastepaper and 10% post-consumer waste.
© 2015 VOLVO CARS OF NORTH AMERICA, LLC
Technical Journal 25477
VST Operation Number
VST Operation Number
36001-2
28466-3
28411-2
Description
Diagnostic Trouble Codes, read / reset. DTCs in VIDA
Engine Control Module, fault tracing DTC
Fuel pump control module, replace
DTC Diagnostic Trouble Codes
Control Module
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
ECM
CEM
CEM
CEM
CEM
Code
2120
2100
291A
260A
2600
2610
261A
291B
291C
291D
2800
280B
280C
280D
2900
290B
290C
290D
962A
961A
3A04
3A05
3A07
3A08
Fault Type
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Permanent
Rows beginning with * are modified
Note! If using a printed copy of this Technical journal, first check for the latest online version.
Text
CSC = Customer Symptom Code
DTC = Diagnostic Trouble Code
Note! If using a printed copy of this Technical Journal, first check for the latest online version.
Page 2 of 4
2015-04-14
Technical Journal 25477
*NOTE! THIS DOCUMENT SUPERSEDES THE PREVIOUS TECHNICAL JOURNAL
25477 DATED 2014-03-28. Prior approval is no longer needed for PEM replacements. PLEASE
UPDATE YOUR FILES.
DESCRIPTION:
Analysis of replaced PEM’s (Pump Electronic Modules) from the field have shown to have no errors. To
prevent faulty replacement and repeat repair please follow this document.
For more information, please see component and function descriptions in VIDA, Design and Function
section 2 Engine with mountings and equipment - > 28 Ignition and control systems -> 284 control
system, fuel supply.
SERVICE:
Fault tracing steps:
Diagnostic Trouble Codes (DTCs) for fuel distribution related faults (customer complaints related to
Check Engine Light (CEL) illuminated):
1. If any of following DTC’s are set (after following the Vida fault tracing and checking the wiring
harness, connectors and fuse/relay) the PEM may be at fault:
CEM 3A04, 3A05, 3A07, 3A08
or
ECM 2610 (B5244S4/B5244S7/B5244T7)
or
ECM 2120 (engine B5244S4/B5244S7/B5244T7)
or
ECM 291B, 291C, 291D (engine B5254T3 2004)
2. The PEM may be at fault if any other ECM DTCs, related to fuel distribution (e.g. fuel trim, fuel
pressure sensor, fuel pressure control etc.), are stored.
However, all possible causes in listed VIDA instructions first have to be investigated.
If any of the following DTC’s are stored, the fuel pressure sensor should be investigated first:
ECM 2600, 2600A (engine B5244S4/B5244S7/B5244T7)
or
ECM 2100 (engine B5254T3 MY2004)
or
ECM 2800, 280B, 280C, 280D (engine B5254T7/B5254T3 MY2005-)
If any of the following DTCs are stored, the fuel pump should be investigated first:
ECM 261A (engine B5244S4/B5244S7/B5244T7)
or
ECM 291A (engine B5254T3 MY2004)
or
ECM 2900, 290B, 290C, 290D (B5254T7/B5254T3 MY2005-)
2015-04-14
Page 3 of 4
Technical Journal 25477
Before determining that the PEM is at fault, quick test of the fuel pressure system (engine B5254T7/
B5254T3) or test of fuel pump (engine B5244S4/B5244S7/B5244T7) should be performed, you can find
this in VIDA Repair -> Cleaning, Inspection and Adjustment -> Section 2 Engine with mountings and
equipment -> 23 Fuel system -> 238 Control system and Fuel system pressure, checking.
If wiring harness connectors and fuse/relay related faults have been dismissed and the quick test proves
that there is a fault, then the PEM should be replaced.
Customer complaints related to crank-no start/long crank time and/or engine stall/hesitation:
If the customer complaint is related to crank-no start/long crank time, engine stall, or engine hesitation
and if there are no DTC’s set, then follow basic fault tracing based on the symptom (e.g. fuel level
check, fuel pressure check, check for proper spark at the plugs, etc.) If any fuel distribution related
DTC’s mentioned above are stored, please follow instructions in point 1 and 2. If all diagnostic is ok
PEM replacement should be the correct repair.
For all DTC’s, frozen values and DTC counters first have to be investigated. Wiring harness, connectors
and fuse/relay related faults need to be checked first.
In all other cases, PEM replacement is the wrong remedy and will most likely end up with repeat repair.
Instead, please follow VIDA instructions to find other possible causes to solve the issue.
Page 4 of 4
2015-04-14
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TSB/Document ID: TJ25477
Replacement Service Bulletin Number:
MFR Communication Date: 2015-04-14
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK
MFR Component System:
MFR Component Subsystem:
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