Cutting out help required please
 

This one is a quite long and a bit tricky, help is required please.
V70 D5 2.4D 2009 163 BHP no flaps Auto.
The car started stalling recently on tick-over, it would always restart immediately and drives ok. It now stalls within 10 seconds of tick-over each time. Yesterday I changed the fuel filter and replaced with genuine volvo filter and it’s no different.
The interesting thing though is that the cartridge filter was crushed in the housing. When I first replaced the filter on buying the car I remember the filter also crushed this too was genuine volvo.
Either the filter is slightly too long by a few mm or the housing is too short by a few mm or the filter is the incorrect one. Last one I bought direct from FRF volvo using the reg number of the car.
A quick look online at 5 various makes of filter show the length of PN 31342922 being from 110.5 mm to 114mm?
Could my Issue be air getting into the fuel line somewhere due to this and low fuel pressure?

To complicate matters but possibly connected when you accelerate hard it goes into limp mode and requires switching off for 1 minute before limp mode is gone. It has always done this in the 2 years of ownership, driving gently no problems misfires or flatspots.

I will attempt to add pictures of my crushed filter and the screenshots from VIDA I took last week in my next post.

Hopefully files attached

Results of VIDA last week

Update:

Car now cutting out whilst driving. the wife has just left the car and got the bus home with the kids.

I'm sleeping in the doghouse tonight.

Any volvo indies in the south wales area I can have it towed to?

Update

After some logical thought and a chat with a volvo specialist, We have guessed that I have a faulty in tank pump that is stopping flow or even running backwards, this is causing the vacuum between the tank and engine and sucking the fuel filter flat.

This evening I will drop the tank remove and clean pump and tank and all should be revealed (crosses fingers)

£300 is a lot for a pump, but if it fixes the car and the long standing limp mode issue I've had from day 1, I will be pleased.

Update tomorrow.

That fuel filter looks quite dirty & has a rusty residue on it? Cleaning the tank might not be a bad idea.

I used a Mann fuel filter in my car. I think they manufactured parts for Volvo in the past, they may well still do. On inspection when I changed mine, the part numbers were the exact same on the Volvo filter as the Mann one!

Your car is a 2009 model. I thought all euro 4's had swirl flaps, or is it only the ones with grey engine covers that do?

Correct a 2009 D5 is Euro 4 and will have swirl flaps.

Mine is 2.4D 163 so no swirl flaps. Yes the volvo filter is made by mahle. Do not use any of the other cheaper copies though.

Did not get chance to remove tank yesterday to test my in tank pump failure theory and off on holiday later, so all you lovely interested people will have to wait until the end of January for the next riveting installment !

See you later

If your car is badged 2.4D & has 163bhp, it'll have the D5244T5 engine more than likely (Its still a D5 engine, just with reduced power output. If it was the 185 bhp version, it'd be badged D5). My car has the exact same engine as yours (163bhp) & has swirl flaps, so I don't know how yours doesn't & its the euro 4 engine? There's also a 175bhp version used in 2009 V70's onwards, with engine code D5244T14. Your car either has that engine, also badged 2.4D & has 175bhp, or D5244T5 badged 2.4D with 163bhp.

I think Volvo just changed the colour of the engine cover on newer models around the year of yours or slightly before, so just because it has a black engine cover doesn't mean it doesn't have swirl flaps (It used to on older models though). As an example, the euro 3 engines with 163bhp had a black engine cover, which had no swirl flaps or DPF (Pre 2007 'P2' shape V70's) - Lots of people bought them for this reason.

The euro 4's (Facelift shape 'P3' V70's - 2007 onwards) have swirl flaps & DPF's (Known as euro 4 engines). That's my understanding of it anyway, but I may be wrong. However, it might be something for you to consider... Check your engine code or ring a dealership, give them your reg number & ask if it has swirl flaps. As far as I know, its a euro 4 engine & it will have them -Its all to do with emissions I think.

Hopefully the fuel tank clean will reveal the issue. One of the VIDA images shows a turbo underboost code. Have you checked the hoses for splits? You might have an air leak, hence why the car goes into limp mode when giving it some beans.

Many people are fully aware that the Euro 3 163bhp engine does not have swirl flaps.

Many people who have the later Euro4 163 bhp Badged 2.4d to indicate what engine is fitted, then wrongly assume that because theirs is a 163 bhp it does not have swirl flaps. They are wrong.