S60 Electrics: - Fuel Gauge.

coaster22 · Jul 30th, 2015, 12:06

I have looked through the forum but couldn't find a similar problem, but perhaps someone out there can help. I have a 2004 S60 2.0T which is a great car.
However I have had some intermittent fuel gauge problems. When turning on the ignition the fuel needle will rise to the correct level then occasionally drop back to zero and stay there until the next restart. Recently after a fill up from half full to full the gauge just stayed at half full, again until the engine was restarted when it then read correctly at full. I have attached a pic showing some possibilities, CEM reset, saddle floats, or DIM , not sure where to start. Any help appreciated. Cheers

Joe Harding · Jul 30th, 2015, 12:21

You have a choice: Fuel senders in the tank (two off, with an umbilical) or connections to gauge.

The first is smelly and you need to thoroughly clean around access hatches before unscrewing them (good luck...) and then grovel around in fuel to retrieve the senders with their floats. Sometimes the problem is here.

Otherwise it could be the DIM. Ours had a problem where the fuel gauge read half full at empty. It was one signal not getting to the summing circuit so it thought the tank was half-full all the time. A dab around with a soldering iron fixed that.

Whichever one you try, DISCONNECT THE BATTERY before you remove anything (including seats)

Lion1966 · Jul 30th, 2015, 12:37

I had the same problem with my 2001 S60 2.0T. Local motor electrical bloke said its the senders but wouldn't get involved in a repair. A couple of local garages didn't want to get involved.
Ended up getting the Volvo dealer to do it. Cost about £580 as it's an entire replacement kit. They showed me the old parts. It was pretty shocking to see they've failed on a 14 year old car but some PPI refund paid for the repairs.
A word of caution if you buy the kit from Volvo. The seals were missing from the kit, the wrong seals were sent as a replacement and to top it all the wires going into the fuel sender section were badly frayed so more replacement parts had to be ordered.
I lost my car for 5 days and Volvo 'customer care' was the worst Ive ever experienced. According to them any problem with parts is between the dealer and the people who supplied them with the parts, Volvo supply the parts so it shows how much they care about customers.
The dealer discounted the repair which was good of them.
The experience was so bad that I didn't bother going ahead with a new Volvo purchase. I'll keep my old one for a while until I make up my mind what to buy.

Georgeandkira · Jul 30th, 2015, 13:03

Hello, After 2 good responses I'm a bit apprehensive to suggest the following.
Note your mileage at each fill-up and live with it.
I know you know to do this and are likely doing it already because your gauge is unreliable.
I gotta think, "at these prices why bother?". Better to spend that money on an A/C fix or almost anything else. Kira

Jul 30th, 2015, 12:21	#2
Joe Harding Premier Member Last Online: Today 07:27 Join Date: Oct 2010 Location: Bristol	You have a choice: Fuel senders in the tank (two off, with an umbilical) or connections to gauge. The first is smelly and you need to thoroughly clean around access hatches before unscrewing them (good luck...) and then grovel around in fuel to retrieve the senders with their floats. Sometimes the problem is here. Otherwise it could be the DIM. Ours had a problem where the fuel gauge read half full at empty. It was one signal not getting to the summing circuit so it thought the tank was half-full all the time. A dab around with a soldering iron fixed that. Whichever one you try, DISCONNECT THE BATTERY before you remove anything (including seats) __________________ "The more people I meet the more I like my God."

Jul 30th, 2015, 12:37	#3
Lion1966 Junior Member Last Online: Apr 30th, 2024 19:41 Join Date: Jul 2013 Location: Croydon	I had the same problem with my 2001 S60 2.0T. Local motor electrical bloke said its the senders but wouldn't get involved in a repair. A couple of local garages didn't want to get involved. Ended up getting the Volvo dealer to do it. Cost about £580 as it's an entire replacement kit. They showed me the old parts. It was pretty shocking to see they've failed on a 14 year old car but some PPI refund paid for the repairs. A word of caution if you buy the kit from Volvo. The seals were missing from the kit, the wrong seals were sent as a replacement and to top it all the wires going into the fuel sender section were badly frayed so more replacement parts had to be ordered. I lost my car for 5 days and Volvo 'customer care' was the worst Ive ever experienced. According to them any problem with parts is between the dealer and the people who supplied them with the parts, Volvo supply the parts so it shows how much they care about customers. The dealer discounted the repair which was good of them. The experience was so bad that I didn't bother going ahead with a new Volvo purchase. I'll keep my old one for a while until I make up my mind what to buy.

Jul 30th, 2015, 13:03	#4
Georgeandkira Premier Member Last Online: Today 02:06 Join Date: Feb 2009 Location: Hackensack	Hello, After 2 good responses I'm a bit apprehensive to suggest the following. Note your mileage at each fill-up and live with it. I know you know to do this and are likely doing it already because your gauge is unreliable. I gotta think, "at these prices why bother?". Better to spend that money on an A/C fix or almost anything else. Kira

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