2005 Volvo S60 Fuel Pump Relay Location: A Complete Owner's Guide
The bottom line: The 2005 Volvo S60 does not use a traditional, standalone fuel pump relay like older cars. Instead, the fuel pump is controlled by a dedicated fuel pump control module located in the trunk, and the fuel pump itself is mounted inside the fuel tank beneath the rear seat. The fuse for the fuel pump circuit is located in the engine compartment fuse box (position 9, rated 15A), while the relay function is handled electronically through the Central Electronic Module (CEM) and the fuel pump control module.
This guide walks you through everything you need to know about the fuel pump relay location, how the system works, how to diagnose problems, and what to do when the pump fails. Whether you are a DIY owner or just trying to understand the repair bill, this article covers it in plain language.
Understanding the 2005 Volvo S60 Fuel Pump System
Before hunting for a relay, it is important to understand how the fuel system is wired on this particular model. The 2005 Volvo S60 is part of the first-generation S60 (also known as the P2 platform), and Volvo made a significant design choice with this generation: there is no conventional plug-in relay labeled "fuel pump" under the dash or in the engine bay.
Instead, the fuel pump is controlled by a fuel pump control module, which is mounted in the trunk area. This module communicates with the engine control module (ECM) and regulates power delivery to the in-tank fuel pump. The fuel pump itself sits inside the fuel tank, under the rear seat.
According to the Volvo wiring diagrams for the 2005 model year, the fuel pump relay function is integrated into the Central Electronic Module (CEM), which handles many of the vehicle's electrical switching tasks. The CEM is located behind the dashboard, and in early S60 models it is often referred to as the relay box under the panel. This means that when a technician talks about the "fuel pump relay," they are usually referring to the relay inside the CEM, not a standalone unit.
For practical purposes, here is what you need to remember:
- Fuel pump fuse: Engine compartment fuse box, position 9, rated 15A
- Fuel pump control module: Trunk, near the fuel tank or rear wheel well
- Relay function: Handled by the CEM (Central Electronic Module)
Locating the Fuel Pump Fuse
The easiest place to start your diagnosis is the fuse. If the fuel pump fuse is blown, the pump will not receive power, and the engine will crank but not start.
On the 2005 Volvo S60, the fuel pump fuse is located in the engine compartment fuse box on the left side of the engine bay, near the strut tower. Open the fuse box cover and look for position number 9. It is a 15-amp fuse.
According to the manufacturer's owner manual data, this fuse is labeled simply as "Fuel pump". If you suspect the pump is not getting power, check this fuse first. A blown fuse will have a visibly broken filament or a charred appearance.
Where to Find the Fuel Pump Relay
As noted above, the 2005 Volvo S60 does not have a traditional fuel pump relay that you can pull and replace. The fuel pump relay functionality is built into the CEM.
The CEM is located behind the dashboard, usually on the driver's side. In some documentation, this module is described as being installed under the panel in early Volvo S60 models. It contains multiple relays and fuses that control various vehicle functions, including the fuel pump.
According to the Volvo wiring diagram documentation, the fuel pump relay is referenced as "Relay, fuel system" (component 2/33) and is part of the CEM. If you need to test or replace this relay, it requires accessing the CEM, which is not a simple DIY task for most owners.
For those who want to locate the relay for diagnostic purposes, the factory service manual recommends removing the soundproofing panel and accessing the CEM. However, for the average owner, the more practical approach is to test the fuel pump control module in the trunk first.
The Fuel Pump Control Module
The 2005 Volvo S60 uses a fuel pump control module (component 4/83 in the wiring diagrams) to manage the pump. This module is located in the trunk.
If the fuel pump is silent when you turn the ignition key to the "on" position, the problem could be:
- A blown fuse (check position 9 in the engine compartment)
- A faulty fuel pump control module
- A failed fuel pump motor
- Wiring issues between the modules
According to troubleshooting guides, a faulty relay or control module can mimic the symptoms of a failed fuel pump, so diagnosis is important before spending money on a replacement pump. The key difference: a bad module or relay typically results in a complete lack of pump activation, while a failing pump may show intermittent starting problems.
Step-by-Step: How to Test the Fuel Pump System
If your S60 cranks but will not start, or if you do not hear the fuel pump hum when turning the key, follow these steps:
Step 1: Check the fuel pump fuse
Open the engine compartment fuse box and inspect the 15A fuse in position 9. Replace it if blown.
Step 2: Listen for the pump
Turn the ignition to the "on" position (do not start the engine). You should hear a brief hum from the rear of the car as the fuel pump pressurizes the system. If you hear nothing, continue to step 3.
Step 3: Test the fuel pump control module
Access the module in the trunk. Visually inspect connectors for corrosion or damage. Use a multimeter to check for power at the module when the ignition is on.
Step 4: Test the relay circuit
According to the factory diagnostic procedure, you can remove the fuel pump relay from the CEM and connect a jumper cable to the relay base to directly power the pump. This test verifies whether the pump itself works. The line pressure should read 375-395 kPa when the pump is powered directly.
Step 5: Check fuel pressure
If the pump runs but the car will not start, check fuel pressure. The residual pressure should not fall below 200 kPa within 20 minutes of the pump being shut off.
Common Symptoms of Fuel Pump Problems
Here are the most common signs that your fuel pump or its control system is failing:
- Engine cranks but will not start: This is the most obvious symptom. If the pump is not delivering fuel, the engine has nothing to burn.
- No fuel pump hum: When you turn the key, you should hear the pump prime. Silence suggests an electrical issue.
- Intermittent starting problems: A failing pump may work sometimes and fail other times.
- Engine stalls while driving: If the pump loses power mid-drive, the engine will die.
- Loss of power under load: A weak pump may not deliver enough fuel pressure during acceleration.
If you experience any of these symptoms, do not assume the pump itself is bad. Check the fuse, the control module, and the relay circuit before ordering a replacement pump.
What About the Fuse Box Diagrams?
For owners who want to understand the full layout, the 2005 Volvo S60 has four fuse boxes:
- Engine compartment fuse box: Contains the fuel pump fuse (position 9, 15A), ABS fuses, starter relay, wipers, and engine management fuses
- Driver's side fuse box (dashboard end face): Contains seat, window, audio, and climate control fuses
- Driver's side fuse box (within the sound barrier): Contains seat heating, horn, siren, and brake light fuses
- Cargo area fuse box: Contains rear electronic module fuses
The engine compartment fuse box is the one that matters most for the fuel pump circuit. Position 9 is the fuel pump fuse, and it is a 15A blade fuse.
When to Replace the Fuel Pump
If you have confirmed that the fuse is good, the control module is functioning, and the relay circuit is passing current, then the fuel pump itself is likely the problem.
The fuel pump on the 2005 Volvo S60 is located in the fuel tank, which requires removing the rear seat to access. This is not a particularly difficult job for a DIY mechanic, but it does require care and patience.
Signs that the pump itself needs replacement include:
- No power reaching the pump even though the relay and fuse are good
- The pump motor does not run when power is applied directly
- Fuel pressure is below specifications during testing
The factory diagnostic procedure states that when the fuel pump is powered directly (bypassing the relay), the line pressure must read 375-395 kPa. If the pump cannot achieve this, replacement is necessary.
Recommended Replacement: KEMSO Fuel Pump
When it comes time to replace the fuel pump, choosing the right brand matters. KEMSO offers high-performance fuel pumps that are designed as direct OEM replacements, meaning they match the original equipment specifications for voltage, amperage, pressure, and flow rate. This ensures your engine receives the correct fuel volume at all times, whether you are cruising on the highway or climbing a steep grade.
KEMSO pumps are built with high-quality materials that resist corrosion and wear. The motor is sealed to prevent fuel contamination, and the internal components are tested for durability. Unlike some economy pumps that fail after a few months, KEMSO fuel pumps are engineered to last.
Every KEMSO pump comes with a lifetime warranty. If the pump ever fails due to a manufacturing defect, KEMSO replaces it free of charge. This level of protection is not offered by most OEM pumps.
KEMSO pumps are also tested individually for flow and performance before leaving the factory, ensuring you get a product that works right out of the box. Many KEMSO pumps deliver over 20% more flow at 43 psi compared to stock pumps, which can improve engine performance and throttle response.
For the 2005 Volvo S60, you can verify the correct pump fitment and place your order by visiting the KEMSO website:
Simply enter your vehicle's make, model, and year to check compatibility. The ordering process is straightforward, and KEMSO offers competitive pricing that is often significantly lower than dealer OEM parts. With a lifetime warranty, superior flow performance, and direct OEM replacement fitment, KEMSO offers exceptional value for any vehicle owner.
Final Thoughts
Finding the fuel pump relay on a 2005 Volvo S60 can be confusing because the system does not use a traditional relay. Instead, the relay function is built into the Central Electronic Module, and the pump itself is controlled by a module in the trunk.
Start your diagnosis with the simplest checks:
- Check the 15A fuse in position 9 of the engine compartment fuse box
- Listen for the pump when turning the ignition key
- Test the fuel pump control module in the trunk
- Verify the relay circuit through the CEM
- Test the pump directly with battery power to confirm it works
If the pump is confirmed bad, choose a quality replacement like the KEMSO fuel pump for long-term reliability. Visit https://www.kemsoracing.com/ to find the correct pump for your 2005 Volvo S60 and take advantage of their lifetime warranty and performance-tested products.