Engine: D5: S60 D5 Intercooler and Black Smoke

[SRPhoto]

So I have notice the odd puff of smoke while towing my caravan last time out. This week while driving solo down to South Wales I noticed the car smoking while cruising at 2000rpm and under acceleration. I also notice the odd miss fire at 1800rpm or so.

While away I took the plenum off as I have cleaned it about 12 months ago, it was sooty (as were the two black pipes) but not blocked.

On my return home I have removed the front under tray that had some oil on it, I also noticed that the bottom of the intercooler was not flat, it is bowed down in the middle and I assume that's not correct!

I connected up my PC and I have a stored code:-
P0244 Turbocharger waste gate solenoid

When the car is rev'ed then loads of air is blowing out from by the cooler and radiators at the front of the car.

So my assumption is the the intercooler is dead (from other things I have seen on here).

I believe I can get a genuine Volvo one for my D5 for about £220 with delivery, anyone know of any better deals (I have not had time to call the dealers parts for a price as I have only got back this evening)

Anyone know of a step by step for replacing the S60 D5 intercooler?

Photos:-
http://smg.photobucket.com/albums/v3...t=IMG_0416.jpg
http://smg.photobucket.com/albums/v3...t=IMG_2627.jpg
http://smg.photobucket.com/albums/v3...t=IMG_2626.jpg
http://smg.photobucket.com/albums/v3...t=IMG_2625.jpg
http://smg.photobucket.com/albums/v3...TCODESMOKE.jpg

Thanks in advance for anyone who can help with my questions and hope the photos and information above can also help someone.

Regards,
Steve.

[Pedro Fandango]

yeh sounds the same as mine's doing. Mine is quite bad & get the black smoke when on half throttle under load, i've also got oil on my slam panel

i'm looking at getting a new intercooler made, the amount of intercoolers that go i don't want to replace it with another thats going to do the same

[macs]

yes, your intercooler's gone. it's not too difficult to replace it, just requires some patience to slide it out the bottom.
get hold of Haynes manual to find out 'how to'.
good luck

[SRPhoto]

Once I do replace it I assume it will be wise to clean out the hoses again and the the air inlet on the top of the engine (that I have never cleaned)?

[SRPhoto]

I have seen somewhere people mention removing the lights and bumper?

The attached pdf does not mention any of this, just remove the fan and drop the inter cooler and radiator out of the bottom.

Anyone have any thoughts on this?

Steve.

[kenny]

i just replaced mine, i thought i had found a real bargin at euro carparts site, put in my reg and it came up with the right car details and they showed an intercooler for £146 plus vat.
I then ordered it through my pals trade account and got it for £119 plus vat.
it was not until i got the old one out and went to fit the new one that i found out it was for a T5.
as every thing was the same apart for it not having anywhere to put the boost sensor on the outlet pipe and i am just about to go on holiday, i fitted it and cut the outlet pipe off the old one and the cut the turbo feed pipe,
i then inserted the old outlet pipe to join it back together. all works fine now.
i followed a thread i found which told me to remove the front bumper, head lights which gives enough room to move the air con rad forward enough without removing any pipes to get the intercooler out.
no lose of coolent gearbox oil or aircon gas. total time hour and a half but i have a ramp and air tools which makes it real easy.

[SRPhoto]

Just got back from the dealers. Was quoted £242 for the inter cooler, but managed to get it off them for £217.85

Time to roll up my sleeves and get it fitted!!

[SRPhoto]

Car now running much better and quicker than its been for many months.

I followed the Volvo way to change the IC leaving the lights and bumper on, a few tips I would give are....
You must empty the radiator (as in the Volvo pdf method above) and can't take a shortcut.
Remember to un-clip the loom off the IC inlet side before dropping the unit.
You do not need to disconnect the expansion tank pipe.
Use wire to hang the AC unit NOT cable ties, they will snap!

http://smg.photobucket.com/albums/v3...t=IMG_2641.jpg
http://smg.photobucket.com/albums/v3...t=IMG_2643.jpg
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http://smg.photobucket.com/albums/v3...t=IMG_2647.jpg

[Dean Barlow]

Hello
Im new to these sites, and i am only twenty one years old but, yes i do drive a Volvo s60 D5 SE and do you know what? i wouldnt drive anything else after buying one.

Ive had the car for exactly two years this weekend its a 53 plate and i havent had any problems with it apart from these past few months.I know a bit about cars myself.when it started smoking badly i was slightly concerned.There was no power loss or anything so i couldnt understand.I took the car to a friend of mine who used to be a mechanic for the police constantly fixing the T5's he suggested changing the egr valve first.I did this and nothing changed.My next option was to change the injectors.Instead of changing the lot i checked every injector and saw one was slightly damp at the bottom which injectors shouldnt be so therfore i changed it but to no avail.I then managed to get hold of a computer to plug it in.This showed up the turbo boost control valve was knackered.I changed that and again,exactly the same.The car had by this point started going into limp mode and i wasnt getting no turbo until 2500rpm.Id got to the point where i thought i need to pull the car apart and find out exactly what was going on rather than keep spending money after money on it.We put the car on the ramps and on going up them i could here a hissing noise from the front of the car.It never made this noise revving it stood still it was only when the engine was under load.I then found the intercooler had warped down and was leaking air when under pressure.....Intercooler changed,problem solved once and for all..

[jaykhan]

hiya i have V70 D5 130k Milage 2003 Model i Have done Ecu Remap and now within a Month Black Smoke started to came from exhaust. I have done EGR Valve clean but still the smoke is there i went back to Garage who did Remap he said to me If the Remap was the fault then Black Smoke should come starightaway not after a Month he told me to check Inter cooler Hose and Injector or Check Turbo Hose or Injector i have spent a Lot money now dont know what exactly to do. So you guys have any idea what exactly can be the Problem after the Remap Volvo on the Higher gear Car Goes fast and No smoke but on lower gears Speed stuck and black smoke comes a lot .

thanks