Engine Control Module (ECM), Fuel Pump - Removal & Installation (Coupe): Other Volvo C70 I

Fuel Pump Unit, Replacing

Special tools

9812270

9812273

9812282

9985972

9995484

9995485

9995561

9995666

9995673

Safety

First see Safety regulations for handling fuel .

Preparation

Draining the fuel tank

To drain the fuel tank, see Draining the fuel tank AWD and 2WD/ORVR (IE00)

If you have drained the fuel tank according to the "non working fuel pump" method continue according to Fitting the fuel pump units and then Fitting the rear suspension assembly .

Draining the fuel system

To drain the fuel system, see Draining fuel injection system .

Scheme 568

Remove the front and rear luggage compartment floor.

Scheme 569

Undo the ABS sensor and fuel level sensor connectors.

Remove the connectors' holder and the front cover.

Feed the leads through the hole.

Scheme 570

Remove the lock ring from the rubber gaiter.

Press the rubber gaiter and filler pipe into the wheel housing.

Scheme 571

Remove

1. rear wheels
2. right-hand wheel arch liner and mudflap.

Scheme 572

Remove the protective cover from the fuel lines.

Removing the protective covers in front of fuel tank

Remove

1. protective covers at front edge of fuel tank (three plastic nuts on each cover)
2. all pipes from the plastic clips on the fuel tank.

Scheme 573

Remove the rear exhaust pipe and silencers.

Scheme 574

Detach the longitudinal stay mountings from the body.

Position an engine lift gently against the longitudinal stay mounting.

Remove

1. bolts for jack attachment and longitudinal stay mounting in body, both sides
2. engine lift.

Undo

1. three-way branching on left-hand jack attachment.
2. front brake pipe from the 4 clips under the car.

Scheme 575

Remove the hand brake cable from the jack attachment by drilling out the pop rivet (B).

Tie the jack attachment to the longitudinal stay brackets (A). Use a cable tie.

Scheme 576

Mark the propeller shaft in relation to the driver.

Note. Note the bolt length and location on the CV joint. See the table below (standard bolts for front and rear CV joints and balancing bolts for rear joint).

Remove the propeller shaft bolts. Use holding tool 9995561 . Move the shaft to one side.

Standard bolts for front and rear CV joints and balancer bolt for rear CV joint

Note. Before removing the propeller shaft from the companion flange: Carefully mark the position of the propeller shaft in relation to the companion flange. Check also whether balancer bolts are fitted. Where applicable, note the position and length of the balancer bolts.

Note. If the previous propeller shaft is refitted without replacement of the rear joint or removal or replacement of the companion flange on the differential, perform the following: fit the propeller shaft using the markings made upon removal . Use new bolts of the same length as those removed. If the propeller shaft is to be changed, the new shaft must be fitted with new bolts of standard length.

Scheme 577

Position the jack 9985972 against the torque tube.

Remove the bolt and lower the torque tube with the engine lift.

Scheme 578

Place the lifting table with fixture under the tank and link arms. (Scheme 578)

Scheme 579

Remove the tank strap bolts from both sides.

Scheme 580

Remove the bolts securing the rear axle member to the body on both sides.

Scheme 581

Carefully lower the rear suspension and fuel tank about 30 cm.

Check that the fuel filler pipe is clear of the wheel arch lining.

Note. Check also that the fuel line between the fuel level sensor and the ejector pump does not foul the body during lowering.

Note. Check that the brake pipes are clear.

Scheme 582

Unhook the fuel lines from their mountings.

Scheme 583

Remove

1. the fuel lines from the fuel pump and ejector pump, use special tool «9995666»(ref-403953-S24236455152011061000000)
2. fuel line attachments between the fuel pump and fuel filter.

Note. Do not remove the fuel line between the fuel pump and the ejector pump.

Removing the fuel lines from the clips

Remove the return line from the ejector pump (left-hand side).

Scheme 584

Remove

1. pump unit on left-hand side
2. pump unit on right-hand side. Use special tool «9995485»(ref-403953-S37993232752011061000000) .

Scheme 585

Install

1. new washers
2. left-hand pump unit
3. right-hand pump unit

Grease all contact surfaces of the pump units' retaining nuts with Vaseline.

Note. Do not apply Vaseline to the nut threads.

Tighten the nuts with 40 Nm . Use special tool 9995673 as a counterhold. The tool's indicator tip must be between the markings on the fuel tank in order for the placement of the pump units to be correct.

Note. Make sure the pump units are correctly positioned so that the fuel gauge shows the correct value.

Fitting the fuel lines

Position and secure the fuel lines to their mountings in the same order as they were removed.

Removing Fuel Line From Fuel Pump

Install

1. Fuel line attachments between the fuel pump and fuel filter.
2. fuel lines from the fuel pump and ejector pump.

Fitting the fuel lines to the clips

Fit the return line from the ejector pump (left-hand side).

Fitting the hand brake cable

Raise the rear suspension about 10 cm.

Remove the cable tie (A).

Fit the hand brake cable with clips, use a pop rivet (ø 4 mm) (B).

Raising the rear suspension with fuel tank

Raise the rear suspension and fuel tank.

Make sure the fuel filler pipe does not foul the wing liner. Make sure the fuel line is clear of the body and that the fuel level sensor line does not get caught in the fuel strap brackets.

Lift up the tank fitting lines and fuel pump lines through the body (hatch).

Note. Check also that the fuel line between the fuel level sensor and the ejector pump does not foul on the body when the rear suspension is lifted.

Adjust and secure the filler pipe's crash protection bracket.

Scheme 586

Apply a couple of drops of threadlock, part number 1161351-0, to each bolt.

Fit all the retaining bolts for the rear axle member.

Note. Before fitting the rear axle to the body, measure the distance between the rear axle member guide ø 16.5 mm holes (A) outside the rear retaining bolts, and the ø16 mm holes furthest to the rear on the side members. The distance between the holes should be 595 mm 2 mm.

Tighten the outer bolts to 80 Nm and the center bolts to 50 Nm .

Fitting the fuel tank EVAP lines

Install

1. brake pipe in the 4 clips
2. fuel and EVAP lines
3. lines to protective cover
4. protective cover, use new nuts and washers
5. protective covers in front of fuel tank.

Scheme 587

Fit the propeller shaft to the driver.

Note. Fit the propeller shaft as marked earlier. Refit the bolts in their original positions.

Check the contact surfaces of the viscous coupling and propeller shaft drivers are clean.

Tighten opposite bolts to 8 Nm . Then tighten opposite bolts to 30 Nm . Use holder 9995561

Start by tightening the same bolt both times.

Scheme 588

Fit the front longitudinal stay mountings and the jack attachments to the body.

Press up the link arms to their normal position.

See Use of tensioner 999 5659

Connect the left-hand three-way branching to the left-hand jack attachment.

Fit the longitudinal stay brackets and the jack attachments using new bolts.

Tighten the three bolts for the longitudinal stay bracket to 65 Nm + 60° .

Tighten the bolt through the jack attachment to 105 Nm + 90° .

Fitting the exhaust pipe

Install

1. rear exhaust pipe
2. silencers.

Note. Check that there is clearance to the heat shields.

Fitting the filler pipe

Fit the fuel filler pipe to the body with the rubber gaiter and lock ring.

Fitting the hatches and connections to the tank fitting

Install

1. front and rear hatch in the body and the connector holder. Make sure the rubber seal around the wiring is properly fitted when the rear hatch is fitted.
2. connectors to the tank fitting, fuel pump and ABS system.

Positioning the luggage compartment floor mountings

Position

1. mounting at front edge of luggage compartment floor. Fit the screws along the rear edge.
2. hatch with the rear floor hatch.

Tighten the screws.

Fitting the rear wheels

Install

1. wheel arch liner and mudflap on rear edge on right-hand side.
2. rear wheels.

Refill the fuel tank.

Test drive and perform functional checks.

Connector, Central Electrical Unit Engine/Transmission Control Module (ECM/TCM), Repair

Special tools: 9512812 , 9512637 .

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Replacing cable terminals

Expose the central electrical unit.

Scheme 589

Remove the insulating plate from the central electrical unit by releasing the catch at the same time as the insulating plate is slid out.

HINT: Use a radio screwdriver.

Scheme 590

Release the catch and slide out the lock mechanism.

HINT: Use a radio screwdriver.

Scheme 591

Separate the connector.

HINT: Use a radio screwdriver.

Press in the locking tab on the cable terminal and carefully pull out the cable and the cable terminal.

HINT: Use tool 9512812 or 9512637 .

Scheme 592

Remove the connector from the central electrical unit by releasing the catches at the same time the connector is slid out on the cable side.

HINT: Use a radio screwdriver.

Open the secondary lock.

Remove the cable terminal.

HINT: Use tool 9512631 .

Scheme 593

Insert the new cable terminal

Insert the new cable terminal in the receptacle housing from the cable side (in the correct position). A click is heard when it hooks into place.

Carefully pull on the cable to check that it is firmly attached.

Ordering software

Order the software according to 9438297 .

Finishing

Check that no diagnostic trouble codes have been stored during the repair.

Test drive the car. Check that the function of the engine is OK.

Engine control module (ECM), replacing (B5xx4T)

Special tools

9995722

Points to observe when replacing the control module

Removing the control module

1. Ignition off. Wait for 2 minutes
2. Remove the cover over the control module box. Put the cover to one side. NOTE: Do not touch the control module's pins with your fingers. Static electricity may damage components in the control module.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
4. Move the upper section of the tool backwards as far as it will go. Pull up the tool
5. Carefully pull up the control module.

Installing the control module

1. Check that no pins or sockets are damaged on the connector.
2. Gently press the control module down into the grooves inside the control module box. Press to the limit position!
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
4. Move the upper section of the tool forwards as far as it will go. Pull the tool up
5. Press the cover into place over the control modules
6. Check that the air ducts are correctly positioned.

Order software. See

After downloading the software or replacing the engine control module (ECM), the throttle unit must be adapted according to vehicle communication input: "Adapting the throttle unit". Remedy as necessary.

Check that no diagnostic trouble codes have been stored during the repair.

Test drive the car. Check that the function of the engine is OK.