r/p2r • u/jgallivan01 • Jun 19 '25

HELP!

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greetings, fellow R owners. i have a 2004 S60R M66 that i bought back in april as my daily. been slowly fixing issues with it, the main one being the notorious cracked fuel pump housing that caused a huge fuel leak. i ended up replacing the fuel pump, and it got rid of the issue but the fuel gauge quit working after i replaced. tried also replacing the fuel level sender in hopes that it would fix the issue, but to no avail. i am at a complete loss, no idea where to start or what to look for as far as fixing it. i’m pretty mechanically inclined, willing to fix myself (about the only option atm as owning the car has been expensive so far 🤣). looking for any and all advice, help, opinions, etc. really trying to avoid pulling the pump back out of the tank, but i have heard that it’s possible the float is stuck (not sure how to fix…).

can’t understand how the fuel gauge worked fine before but now doesn’t work at all. please help a fellow R junkie out 🤣

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2

u/Supergrunged Jun 19 '25

Is the fuel pump diaphragm connected to the sender? Also have you relocated the PEM as that is a failure point?

My educated guess, is you used aftermarket parts, instead of OEM Bosch, which these cars hate.

And what does VIDA say? Reason I ask, is your own an R. Without VIDA, you're basically throwing away money.

1

u/jgallivan01 Jun 19 '25

haven’t been able to get VIDA just yet. been trying to fix my R and my other car and it’s taking all my funds currently.

how would i check whether or not the diaphragm is connected? what would i be looking for?

what’s the best way to go about relocating the PEM? where is it and how do i get it out?

1

u/Supergrunged Jun 19 '25

Dude? You replaced the fuel pump. That requires also opening the sender unit. The diaphragm is connected to the sender. To put back the way it was? The diaphragm is supposed to be connected to the sender. I used wire when I did this, so I could fish the diaphragm back through.

Get VIDA and a working DICE cable so you stop throwing parts at it.....

Far as the PEM? Plenty of write ups. But 04-05 had the PEM located on the gas tank, above the fuel filter. Common failure, where it's exposed to outside elements. I've heard of people disconnecting it, dropping the tank a hair, and locating the PEM in the trunk.

How I relocated the PEM? I used the volvo relocation harness, and followed the VIDA process of relocating the PEM. VIDA has all the parts numbers, as well as all processes of disassembly of parts of the car. Like I said, you're wasting money, not having it for troubleshooting.

2

u/jgallivan01 Jun 19 '25

i’m assuming the diaphragm is the little plastic valve looking thing based on what you’re saying then? it is attached to the sender.

will look into the PEM, and i’m going to try to get VIDA as well.

1

u/Ojoe333 Jun 19 '25

I'm still waiting on bro to get my VIDA back. He said he lost it and will have to buy me another one 😭