Problems With Fuel System S60 D5

griffin100 · Apr 11th, 2012, 16:25

New to the forum so apologies if this question has been asked before (I did a quick search but couldn't find an exact match).

I have a 2003 D5 with 223,000 miles on the clock. About 4k miles ago it cut out for no apparent reason on the motorway with an 'urgent engine service required' message. I managed to get it started after a few minutes and got it to a main dealer who diagnosed a 'low fuel pressure' problem and replaced the fuel filter. They also advised not letting the fuel level drop too low as this could cause problems - the level was quite low when it died. That seemed to solve the problem but last week I let the fuel level get low and again the engine cut out on the motorway. It took a while but I managed to get it restarted, filled the tank and it's been ok for the last 200 miles.

Given that the fuel filter was replaced only 4k miles ago is it likely that I have a problem with my tank? - a build up of debris in the tank or a problem with the in-tank filter / pump maybe? I don't want to give it back to a main dealer with the associated high costs, I'd rather give it to the local mechanic whose looked after it for me for the last 150k + miles. With that sort of mileage on the clock the cost of main dealer repairs could be more than the car is worth. Any suggestions as to the problem would be great. One other thing to say is that I'm based in Ireland and we have a problem with laundered and substandard diesel in many garages so I'm wondering if this is an issue also.

Bernard333 · Apr 11th, 2012, 17:10

Yes could be the in tank pump , its a problem thats dogged my V70 for a long time and I sometimes wonder if dirty diesel had anything to do with it . I fitted a T5 petrol pump to my D5 about two months ago , I am not suggesting you try this , I did it because I had one handy but it seems to work ok , I have no idea if there will be long term damage due to the higher pump pressure . You can pick them up complete with cross feed pipe and senders for £20 , you need to carefully remove the metal pump from the plastic housing and then plumb it into the diesel plastic bits , I think any 38mm body electric pump will do . You can check the sludge situation by removing the in tank pump and then unclipping the plastic pot surrounding the pump , you may see some sludge in the bottom of the pot which would then give you some idea if the tank needs cleaning . There is a gauze filter clipped on the bottom of the metal pump body and a second one on an intake pipe inside the pot , check both are clear .

chopper_harris · Apr 12th, 2012, 22:21

You can get a sense of the cross tank shennanigans here :

http://www.volvoforums.org.uk/showth...t=59686&page=2

carl4u44 · Apr 12th, 2012, 22:45

I agree with the above. Start with replacing or testing the in tank pump, there 260£ new for the d5 but worth it as it was a revised updated pump.

Been there with the same symptoms as you only mine totally died.

griffin100 · Apr 16th, 2012, 12:40

Thanks for the info, much appreciated. Will have a look at the in tank pump.

chris vince · Apr 16th, 2012, 18:46

Did you have the 'fuel tanker drivers strike' panic in Dublin?
Most garages over here have never had their storage tanks go so low, if not run out altogether.
You may have bought the muck/water from the bottom of a storage tank?
Chris

LJD · Apr 16th, 2012, 20:35

I had same problem last week
Turned out to be the pump

Bought one from scrap dealer (wrong one supplied !) but all fine now

You can use a Petrol one BUT AND I MEAN BUT ! swap the regulator over .otherwise your car will be going nuts trying to start with such high pressure !!

make sure they also use a NEW gasket etc and check the gauge is working

it was a nightmare for me , but all ended well

Good luck

second hand D5 complete pump system is about £80.00

petrol, £30.00 .Up to you !

griffin100 · Apr 19th, 2012, 19:33

Quote:

Originally Posted by chris vince

Did you have the 'fuel tanker drivers strike' panic in Dublin?
Most garages over here have never had their storage tanks go so low, if not run out altogether.
You may have bought the muck/water from the bottom of a storage tank?
Chris

No there was no risk of a fuel strike in Ireland, howeve we have a big problem over here with laundered diesel. Diesel for agricultural use which is coloured green for identification and is much cheaper than garage bought diesel is washed with acid to remove the dye leading to a product that can cause serious engine damage. It's reckoned that many 'reputable' garages are buying this washed diesel and selling it on to the unsuspecting motorist.

chris vince · Apr 19th, 2012, 19:56

Over here the agricultural diesel (1/2 the price) is coloured red, instead of 'washing' the colour out I have seen an advert for blue dye.
The fella selling it reckons that our laws only refer to red as being duty free, he thinks as there is no mention of blue he can get away with it.
I reckon he is due for a holiday at her majesties pleasure.
Chris

Apr 11th, 2012, 16:25	#1
griffin100 New Member Last Online: Apr 19th, 2012 19:33 Join Date: Apr 2012 Location: dublin	Problems With Fuel System S60 D5 New to the forum so apologies if this question has been asked before (I did a quick search but couldn't find an exact match). I have a 2003 D5 with 223,000 miles on the clock. About 4k miles ago it cut out for no apparent reason on the motorway with an 'urgent engine service required' message. I managed to get it started after a few minutes and got it to a main dealer who diagnosed a 'low fuel pressure' problem and replaced the fuel filter. They also advised not letting the fuel level drop too low as this could cause problems - the level was quite low when it died. That seemed to solve the problem but last week I let the fuel level get low and again the engine cut out on the motorway. It took a while but I managed to get it restarted, filled the tank and it's been ok for the last 200 miles. Given that the fuel filter was replaced only 4k miles ago is it likely that I have a problem with my tank? - a build up of debris in the tank or a problem with the in-tank filter / pump maybe? I don't want to give it back to a main dealer with the associated high costs, I'd rather give it to the local mechanic whose looked after it for me for the last 150k + miles. With that sort of mileage on the clock the cost of main dealer repairs could be more than the car is worth. Any suggestions as to the problem would be great. One other thing to say is that I'm based in Ireland and we have a problem with laundered and substandard diesel in many garages so I'm wondering if this is an issue also.

Apr 12th, 2012, 22:21	#3
chopper_harris Senior Member Last Online: Jan 1st, 2022 18:09 Join Date: Jul 2007 Location: Standish	You can get a sense of the cross tank shennanigans here : http://www.volvoforums.org.uk/showth...t=59686&page=2 __________________ V70 D5 SE Geartronic (2004, 163bhp) Winter Pack, R/Spoiler, Towbar, T5 Brake U/G

Apr 11th, 2012, 17:10	#2
Bernard333 Premier Member Last Online: Oct 20th, 2021 11:41 Join Date: Nov 2007 Location: Ramelton	Yes could be the in tank pump , its a problem thats dogged my V70 for a long time and I sometimes wonder if dirty diesel had anything to do with it . I fitted a T5 petrol pump to my D5 about two months ago , I am not suggesting you try this , I did it because I had one handy but it seems to work ok , I have no idea if there will be long term damage due to the higher pump pressure . You can pick them up complete with cross feed pipe and senders for £20 , you need to carefully remove the metal pump from the plastic housing and then plumb it into the diesel plastic bits , I think any 38mm body electric pump will do . You can check the sludge situation by removing the in tank pump and then unclipping the plastic pot surrounding the pump , you may see some sludge in the bottom of the pot which would then give you some idea if the tank needs cleaning . There is a gauze filter clipped on the bottom of the metal pump body and a second one on an intake pipe inside the pot , check both are clear .

Apr 12th, 2012, 22:45	#4
carl4u44 Master Member Last Online: Sep 7th, 2023 17:21 Join Date: Feb 2009 Location: kk	I agree with the above. Start with replacing or testing the in tank pump, there 260£ new for the d5 but worth it as it was a revised updated pump. Been there with the same symptoms as you only mine totally died.

Apr 16th, 2012, 12:40	#5
griffin100 New Member Last Online: Apr 19th, 2012 19:33 Join Date: Apr 2012 Location: dublin	Thanks for the info, much appreciated. Will have a look at the in tank pump.

Apr 16th, 2012, 18:46	#6
chris vince Junior Member Last Online: Sep 6th, 2023 08:59 Join Date: Oct 2009 Location: Dorset	Did you have the 'fuel tanker drivers strike' panic in Dublin? Most garages over here have never had their storage tanks go so low, if not run out altogether. You may have bought the muck/water from the bottom of a storage tank? Chris

Apr 16th, 2012, 20:35	#7
LJD I've Been Banned Last Online: Oct 22nd, 2021 18:48 Join Date: Mar 2012 Location: london	I had same problem last week Turned out to be the pump Bought one from scrap dealer (wrong one supplied !) but all fine now You can use a Petrol one BUT AND I MEAN BUT ! swap the regulator over .otherwise your car will be going nuts trying to start with such high pressure !! make sure they also use a NEW gasket etc and check the gauge is working it was a nightmare for me , but all ended well Good luck second hand D5 complete pump system is about £80.00 petrol, £30.00 .Up to you !

Apr 19th, 2012, 19:56	#9
chris vince Junior Member Last Online: Sep 6th, 2023 08:59 Join Date: Oct 2009 Location: Dorset	Over here the agricultural diesel (1/2 the price) is coloured red, instead of 'washing' the colour out I have seen an advert for blue dye. The fella selling it reckons that our laws only refer to red as being duty free, he thinks as there is no mention of blue he can get away with it. I reckon he is due for a holiday at her majesties pleasure. Chris

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