S60 D5 Starting from cold problem

Also, does anyone know if it is possible to buy the injectors and then have them fitted at an independent garage as this would hopefully reduce the overall cost.

We seem to be having the same problem with cold starting.

Forget the clever electronics and go back to diesel basics. When you turn a diesel on and the glo plugs come on they use a lot of power. Generally the surrounding dash warning lights light dip slightly. When the orange light goes off the other lights - interior, dash warning etc brighten up slightly. If this doesn't happen chances are your glo plugs are not working. The next stage is to check that 12V is getting to the glo plugs. On my S80 although the orange light comes on there is no power going to the plugs - I've checked with a meter. wiring diagrams are scarce but on a heavy load like this you usually switch via a relay. My understanding is that the affected relay is in the engine bay LHS and is on the bottom layer of relays . Earlier posts have suggested that this relay disintintgrates. 60 to 80A DC is a terrible electrical load especially on a relay that probably costs Volvo thick end of a fiver!

This is crude but I'm sticking with basics. With the acoustic top of the engine removed pour hot water from the tap on and around the injectors. I'm talking a few litres. (fan heater is an alternative) Give the car a little time for the heat to get through and you will find your car will start. (next stage with the old trucks was a small fire under them - probably not so good!)

If the engine starts smoothly and runs smoothly I reckon you can discount injectors. My understanding is that the injectors switch between operations - the swirl pattern changes to reduce diesel knock.

although not a recall Volvo do realise they have an injector problem on a few cars and are contributing towards the cost. My issue is that the main dealer wants a £100 notes just to tell me the glow plugs don't work - still wants to change the injectors and wants to relieve me of copious amounts of cash.

One of the suggestions was that I shouldn't have traded my old Citroen in and with the Volvo dead on the drive I'm beginning to think this would have been good advice. Most mechanics seem scared of the S80 (and probably S60)

[alek]

Hi,

Im planning on buying a 52 up to 53 plate S60 D5 around 60000 miles for about 7000 pounds fairly soon. Can anyone offer advice on how to spot an injector problem when I am looking at cars?

Weather is warming up now so I wouldnt get a chance to check cold start. Does the problem kick in after a certain mileage? Any other symptoms than difficulty starting?

If I happen to miss it, can I buy aftermarket injectors and get a non-volvo dealer to fit them?

Thanks in advance!!

Alek

[palwing]

52 plate V70 D5 auto - 99500 miles..cold start problem this AM for the first time. After about 3 mins of cranking, it started. Outside air temp around 7'C after a chilly night. Heater coil light worked as normal.

Volvo dealer quoted £250/injector plus labour.

So, taken the car to a local Volvo specialist. No fault codes showing, mechanics reckon it's an injector problem. They have quoted me £30/injector to have them checked + 1 hour labour (£52 +vat) to get them out and in. They can get any faulty injectors refurbished for £125 each with 1 yr guarantee. That sounds cheaper than Volvo!

Car is at the garage now. Should know more in the next few days. Will keep you posted.

If this works, I will give people the garage details for those that are interested. They have done work for me before and are very good. Garage is in Norfolk.

[palwing]

Originally Posted by palwing

52 plate V70 D5 auto - 99500 miles..cold start problem this AM for the first time. After about 3 mins of cranking, it started. Outside air temp around 7'C after a chilly night. Heater coil light worked as normal.

Volvo dealer quoted £250/injector plus labour.

So, taken the car to a local Volvo specialist. No fault codes showing, mechanics reckon it's an injector problem. They have quoted me £30/injector to have them checked + 1 hour labour (£52 +vat) to get them out and in. They can get any faulty injectors refurbished for £125 each with 1 yr guarantee. That sounds cheaper than Volvo!

Car is at the garage now. Should know more in the next few days. Will keep you posted.

If this works, I will give people the garage details for those that are interested. They have done work for me before and are very good. Garage is in Norfolk.

See here: http://www.volvoforums.org.uk/showth...t=48897&page=3

[shimon340]

please remember volvo do not manufacture the injectors and didnt design them. The D5 uses a BOSCH fuel system and the unreliability of the injectors comes down to either a design fault or a production concern at Bosch. Im aware Bosch have had instances of a volume of injectors being faulty across all their product lines but Im not privy to the exact situation with the injector model used in the D5.

Volvo contributing etc and being aware of the fault is a result of dialogue with Bosch. either volvo asking them "what's going on!!?" or bosch volunterring the info.

volvo supporting goodwill towards replacement is indeed goodwill on their part and most likely also because Bosch is picking up the costs too.

Bosch is one of the better manufacturers but all have problems from time to time.

Common rail (and unit injectors but this doesnt apply to the D5) are very precise and in some ways 'delicate' or sensitive components. Truth be told, common rail systems are not as reliable as the previous mechanical injector systems. but....emission regulations and NVH reasons mean it is necessary to use it (first being more relevant)

[morris]

Had the car a week, this cold spell now and the car wont start. Only 2 out of 5 plugs at 1.2ohm rest 0ohm. It was starting albeit roughly before then. Forum focuses on injectors. I am looking at the valve clearances. On ohc alloy heads the valve wear results in closure of the gap between shim and cam over time. Most places don't check it any more as the wear rate is so small now. However once the gap closes, on a cold snap the exhaust valve most probably is jacked open and no compression is available on cold start.
I had this on an Isuzu engined Astra and a Citreon AX. Check the clearances as a set of shims is a lot cheaper than a set of injectors. I also have a BMW 325TDS which interestingly has developed the same problem at the same time.

[Clan]

Luckily the D5 has hydralic cam followers so this wont be a problem ...

[morris]

I think unlucky more like.

[v8disco]

The Bosch injectors used by Volvo are no more or less reliable than any other CR diesel injector. Most Ford/Renault models use Delphi injectors and these are much more unreliable than Bosch.

The main problem is that we are demanding higher and higher performance from products like these, and reliability suffers. It has been said to me that injectors such as those on the D5 are working at approx 98% duty cycle, as opposed to petrol or early diesel injectors which operate at around 50%. Any part that is working at almost full capacity will not last as long as long as one that is only working at half capacity.

Poor cold starting on a D5 is likely to only be down to one or two faulty injectors. Do a leak off test, identify the faulty units and swap them.