Electrical issue on 2004 Volvo S60

Car has intermittent electrical issues, have been occurring sporadically over entire lifetime of car. Upgraded DIM and CEM software. Want to replace CEM (under emission warranty) but dealer won't unless there is an emission-relation error code. Dealer suggested replacing DIM for $1800. Check out the codes below and let me know what you think. ------------------------ Error codes from November 2009 visit: AUM-E003 Configuration fault, Faulty configuration BCM-0100 Communication between control units, Communicational problems with ECM BCM-E003 Configuration fault, Faulty configuration CEM-1A62 Communication with ECM control module, Signal missing CEM-1D08 Control module, Internal fault DDM-0025 Mirror motor, Signal missing DIM-E003 Configuration fault, Faulty Configuration PSM-E003 Configuration fault, Faulty configuration SRS-00D5 SRS lamp, Configuration fault ------------------------------ Error codes from July 2010 visit: CCM-E003 Configuration fault, Faulty configuration DDM-0025 Mirror motor, Signal missing PSM-E003 Configuration fault, Faulty configuration CEM-1A23 X-supply relay circuit, Signal missing CEM-1A25 Relay Ext X2-Supply Signal too low CEM-1D07 Control module, Internal fault CEM-1D08 Control module, Internal fault CEM-3F03 Shift lock signal, Signal too low CEM-6C48 Transponder type, Faulty signal CEM-1A21 Relay Ext X-Power supply, Signal too high CEM-1A24 Replay Ext X2-Supply Signal too low CEM-1D0C Control module, Internal fault DIM-E003 Configuration fault, Faulty configuration AUM-E003 Configuration fault, Faulty configuration BCM-E003 Configuration fault, Faulty configuration BCM-0150 Stop (brake) lamp switch, Signal outside its permitted range PDM-E003 Configuration fault, Faulty configuration PDM-E003 Configuration fault, Faulty configuration PDM-0030 Rear view mirror potentiometer, Faulty signal PDM-0032 Rear view mirror potentiometer, Faulty signal

by in Indianapolis, IN on July 03, 2010
2 answers 6 comments
ANSWER by on July 03, 2010
Those internal fault codes for the CEM would make me suspicious of the CEM. What are the symptoms?
COMMENT by on July 03, 2010
Restarting the car usually (though not always) fixes all symptoms except for "SRS Airbag Service Urgent" which needs to be reset by the dealer. When it doesn't fix all the symptoms, the dealer does a "hard reboot" (not sure what that is). But none of this solves the underlying problem, the next flare of symptoms can be a couple hours away or several months away. Although the severity of each episode can vary and not all symptoms may occur with every episode, it just makes for an unreliable car. The full list of symptoms in order of frequency (high to low) is as follows: Trip odometer reset Dashboard dies (all gauges and lights) "SRS Airbag Service Urgent" message Electronics die (turn signals, A/C, radio, power windows, power locks, power seats) Headlights clicking "Brake Failure - Stop Safely" message Time reset Loud thud sound (as if ABS is malfunctioning) Engine stalls Transmission stuck in third gear (slow acceleration, engine overheats) Someone told me that since there are both high speed and low speed communication errors, the CEM must be at fault since these two never interact and are only processed at the CEM. If you agree, do you have a suggestion as to how I could get Volvo to replace the CEM under the following warranty? https://www.customers.volvocars.com/owners/docs/2004/2004_warranty/2004_warranty_02.html
COMMENT by on July 03, 2010
I've not worked on these cars for a few years so I'm a little rusty, but I remember seeing issues with the ABS and CEM modules, and you could have a communication bus error. These problems are hard o diagnose and understandably they don't want to start paying for parts that may not fix the issue, but you need to stay on them and be persistent to get them to address this. I suggest contacting the Dealer General manager and Owner, Volvo Customer support and make sure the Dealer is in communication with the Volvo Field Engineer that is supposed to help address these type of issues. Good Luck!
ANSWER by on June 05, 2014
Did you ever get this fixed? I am having the exact same problem with no answers even from Volvo.Been following many forums and there are a ton of these cars with the same problems and Volvo can't even diagnose the pproblem. And I only have this problem in the summer when it's hot. It's so weird.
COMMENT by on June 07, 2014
Unfortunately, no. I tried out some repairs (costing hundreds), but I never felt confident enough in anyone's theories (both forums and mechanics) to go so far as to start replacing modules (costing thousands). I had bought the 2004 Volvo in 2006 from a car auction. It was a lease return. In the process of investigating these electronic issues years later, I did find out the car had been in a front-end collision as some of the rails (parts of the car's frame) were bent. At that point, I couldn't be sure if that collision was solely responsible for the electronics, exactly which parts I'd need to repair to isolate the gremlins running around in its systems, or if I'd even be able to hold any specific mechanic responsible for his repairs as the problems were unpredictable and flared up at random times. (I think it was more often in the summer, though not exclusively.) I love sinking my teeth into projects and solving complex puzzles, but when I can't be sure my car will get me from A to B without stalling on the highway with little hope for a long-term resolution, I knew it was time for it to go. I traded the 2004 Volvo S60 with 91,000 miles into a dealer in 2012 for $5,700 as I purchased a new car.
COMMENT by on June 14, 2014
I am also having the exact same problems. Please let me know if you figure anything out. This is the first forum I have found, after months of searching that lists the exact problem I am having.
COMMENT by on June 14, 2014
I can forward you a link that helped me. Send me an email to lisa9179@gmail.com. It didn't cost me anything and was the only thing that has helped me.
COMMENT by on July 14, 2014
Hi Can you please forward on any help to alexcain09@gmail.com my c30 is going through the exact same thing dont mind paying for the repair but i just dont trust the advice being given each person has a different opinion of the cause. My c30 is coming up with brake failure lights an abs issues. Any help would be appriecated
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