Ecm 6805 and boost related issues
 

there seems to be a lot of the above rearing its ugly head so i have put together a list of what may be the culprit and a what to check and how to check..
first picture tells you what the code is with an explanation.
things to check are.
INTERCOOLER.
check the tell tale sign by looking under the front bumper you will see oil deposits and also by looking down in the engine bay between the engine and the cooling fan at the bottom, if you still suspect the INTERCOOLER you can have it presure tested insitu.
ENGINE MOUNTS.
front and rear. these receive vac at idle, over 1500rpm the are deactivated.to check these to see if they are leaking block them off and take it for a spin if you still get any issues then its not them.
VNT.
the vnt is activated by vac. to test to ensure the vacuum regulator and lever are working as it should you will need a MITTY VAC,
http://www.uktools.com/mityvac-auto-...2bcc01cbdb1ef7
this is better to get to from under the car on ramps, connect the mitty vac to the regulator in line and create a vacuum the arm should move freely until it stops if it does not there is too much carbon build up on the veins have a look here.
http://www.youtube.com/watch?v=UWyN5...eature=related.
if it is not smooth use the mitty vac to try and free it.carbon build up is the main culprit, italian tune up comes to mind.
TCV
turbo control valve, this is just to activate the engine pads, there is a direct feed from the vac pump to the TCV and then to the engine pads. to check if this is working if you have the volvo diagnostic kit there is a test you can do on there failing that you can hook a vac gauge in line one of these.
http://www.amazon.co.uk/Vacuum-Fuel-...4193334&sr=8-9.
at tickover it should read about 5 hg rev it past 1500rpm and the needle should not move on the gauge. the line in to the TCV from the vac pump should be approx 45 hg at 2500rpm.
TCG.
turbo control governor which is bolted to the engine see this post for identification.
http://www.volvoforums.org.uk/showthread.php?t=122032.
to test this connect vac gauge to out port on TCG in line and the reading should be approx at idle 5hg at 2000 rpm 43hg at 2500 rpm it drops down to 35 hg. there is also a test on vida to check that the VNT is working picture 2.
SOFT CHARGE AIR HOSE.
this is the hose that connects to the turbo check this post.
http://www.volvoforums.org.uk/showth...air+inlet+hose.
when it get old and goes soft excuse the pun it will under load squash and will restrict the air flow to the turbo. also check all other intake hoses.
INJECTOR TEST.
to ensure that you have no issues with the injectors have a leak of test done.
VAC PUMP.
this is situated at the side of the fuel injection pump, this provides vacuum to the TCV and the TCG, connect a vac gauge in line and the reading should be approx at 2500 rpm 45 hg.
FUEL FILTER.
change it
the above hg figures where taken from my car today and as far as i am aware i have no boost issues.
i hope that the above info will point you in the right direction of what to check and the possible fixes,ECM6805 is time consuming and if put into a garage could be expensive to rectify.good luck on your quest and hope that the above will help you .
thanks to all that have posted in the links that i have provided.
mike

Huge thanks - I'll take this done my local garage.

Eds - is there any chance we can make this a sticky as it's currently spread over numerous threads?

I'll take this done my local garage.

http://www.ywseo.net/seo4.jpghttp://www.ywseo.net/signature.jpg
http://www.crfootball.com/xiaoliu3.jpghttp://www.ywseo.net/uk.jpg

Top write up Mike!

I'll take this done my local garage.

http://www.semservice.org/3.jpghttp://www.semservice.org/4.jpg
http://www.semservice.org/5.jpg
http://www.ywseo.net/uk.jpg

turbo clean. with instructions and vids thanks to Fred
http://www.volvoforums.org.uk/showth...=132550&page=9

One more addition related to the mentioned issue: http://www.volvoforums.org.uk/showthread.php?t=138745

Ecm6805 - possible cure
 

I thought I would post this here, as it is particularly relevant to ECM 6805 and Limp Mode.

You MIGHT be able to avoid spending money and getting oily by having a look at Posts 118 and 119 of D5 ISSUES - TURBO ADJUSTMENT which is in the Diesel Engines section of this forum. It just occurred to me that people might be looking at this thread, and have missed the information in the Diesel Engines section.

So far, after about 6 weeks of employing this method, I`ve had no Limp Mode, whereas the car was previously going into Limp on every journey.

Hope this helps someone.

Both of these are related to this thread http://www.volvoforums.org.uk/showthread.php?t=132550

Just to make it easy to find.

Still no recurrence of Limp Mode after a few thousand miles and five months, by regularly "exercising" the turbo as above. Well chuffed.

I've had a lot of problems over the last many months with this fault code, see here:

http://www.volvoforums.org.uk/showthread.php?t=163422

Well, the saga finally ends!

After much investigation and replacement of parts that looked or tested as marginal, including a new intercooler - estimated £50 test v £120 replacement seemed a waste of money so just replaced it - and a full EGR clean without improvement, I resorted to applying logic and started looking outside of the normal ECM6805 causes listed in VIDA.

Turns out that the new exhaust front section 1st CAT had come adrift internally and was restricting exhaust flow causing poor flow at the turbo and low boost. Luckily I had retained the old, fractured exhaust so I had the old parts re-welded by a local fab shop for £40 (they wern't corroded, just fractured, but that's another Kwik-Fit useless parts story!) and substituted the old for new.

BINGO! The beast is back!

When all else fails, check the improbable. Perhaps the exhaust condition should be added to the list of ECM6805 checks?

Many thanks for all the help from the forum members over the last many months.

Steve

sorry for posting this here but you seem like a expert.. :)
 

Dear Outnumbered,

you look like a expert on volvo's, mabey you could help me.. (wanted to send you a PM but need 30 posts to do that and as i just bought the volvo i don't have these yet)

i bougth a V50 2004, the only trouble i expirianced was no boost bellow the 2200 rpm and no error's on the dash, so hoped a vacuum hose lose or something like that (what i think is strange cause you should get a service light?!)

did a diagnostic and got the reading "U0301 Software Incompatibility with ECM/PCM"
thought this was because it was chipped but i found out i got no fuse (20A) in the ECM/PCM slot and no fuse in the vacuum pump slot...

could you mabey take a look at my theat?
http://www.volvoforums.org.uk/showthread.php?t=177588


i would really apriciate it!

kind regards,
Freek from Holland

Great info - need to work through this again.

Steve O.

Don't forget to check that all your hoses are correctly positioned and correctly fitted for the exhaust manifold/turbo. My 6805 was down to this after an engine install. Too much air getting in ran the engine lean, leading to 6805 & melted pistons.

Had the dreaded limp mode issue on my V70 D5 - Read all the posts here and thought it might need a turbo clean etc.

Applied a little lateral thinking and used Redex for diesel in the next few tanks full - hey presto, all fixed and runs like new for less that £10.

If there's a problem try the simple things first ;-)

MAP sensor fault
 

Thanks for the in depth report - priceless for anyone having these issues like myself. I checked bloody everything and it was so intermittent I couldn't trace it. Using a generic fault code reader P0244 kept coming up, but when I tried a different one from a garage 6805 was the reading. Manifold absolute pressure was the problem, sensor was at fault. I removed it, took for a spin for a couple of days and no issues at all with less grey smoke than before. Replaced with a new one (incredibly hard to put back in by the way because of the rubber seal) and sorted at last! A good or appropriate code reader is an absolute as the fault p0244 had me running around in circles!
Hope this helps someone
Karl

When you say 45hg vacuum, is it in mm-hg or in-hg?

Thanks Mike
I have a V70 D5 163bhp 2004 with around 115k. I had the dreaded ECM6805 code diagnosed by a local garage but they weren’t sure how to resolve the issue as Volvos are not their specialism. Booked the car in with the main dealer who confirmed the code running a diagnostics and investigation (costing £60) to test the vac lines which showed no issues and suggested I rebook the car in for a further diagnostics assessment by the Master Technician (who was on holiday at the time of the first visit). I declined their offer of paying a further £100 and decided to carry out searches on the web and I landed at the Volvo Forum. I came across your post with what seemed to be a very useful guide/checklist to work through which would hopefully eliminate the problem and restore the V70 D5 back to its former best. I am not a mechanic and am going through a steep learning curve.
As I was on a tight budget, the first job I decided to tackle bizarrely (for the cost of the gasket set) was to get the turbo out and give the internals a de-coke. Having read up how to do it (I did find a really good set of step by step instructions) ... how hard could it be! 12 hours later job done. Fire up the engine, sounds fine and took car for a spin. Wonderful, accelerate hard and pulled like a train. Revved well past the 2500rpm problem point and no sign of any problems ... for about 3 weeks. Then the problem came back. That was last October. More surfing the web as a result.
I have recently invested some more time and money trying resolve the problem including the following new parts:
1. New Turbo Control Governor (operating the turbo actuator)
2. New Turbo Control Valve (for the engine mounts)
3. All the small bore rubber vacuum pipes replaced with silicone hoses (used 5mm int dia).
I have invested in a Mity Vac as identified in your article to check all the vac pipe pressures and this is now where I hit a strange anomaly. According to your article the main vac pressure at idle should be around 45 Hg. My Mity vac only goes up to 30 Hg but I only get an idle pressure of 22 Hg. Revving up to 2500rpm this figure rises slightly to 24.5 Hg and doesn’t go any higher.
Using the Mity in line between the TCV and the engine mount at idle is 22 Hg (which give the softer engine mounts). Increasing the revs above around 1100rpm the reading drops to 0 Hg (meaning harder mounts) and doesn’t change once over 1200rpm.
Working from underneath (it seemed easier) I connected directly to the VNT and the arm moves pretty smoothly in and out using the Mity vac. I did this several times just to make sure. Then connecting the Mity in line with the VNT I get the following readings. At idle 22 Hg, at 1500rpm 21Hg, at 2000rpm 14 Hg, 2500rpm 11 Hg, 3000rpm 8 Hg and at 3500rpm around 6 Hg. It is these readings on the VNT side of the TCG that baffle me. The article I says the reading at idle is 5Hg, at 2000rpm 43Hg and at 2500rpm 35Hg. My readings seem to do the complete opposite curve.
I thought I was very systematic in changing all the vac pipes by only changing one length at a time to avoid mixing up which vac pipe connected to the inlet and outlet ports on the TCV and TCG. Is it possible that I have still managed to transpose them somehow? For ease of identification I even used different colour silicone hoses for the turbo pipe and vac inlet.
A test run in the car after changing the vac lines, TCG and TCV has made no difference under hard acceleration. Under very gentle acceleration building up the revs in 4th very very slowly on a long stretch of dual carriageway we got to 3500rpm with no issues. Once I had eased off and then tried to overtake ‘with gusto’ same old problem .... instant limp mode which is real a problem halfway through overtaking!
The next item on the list to change seems to be the turbo fresh air intake hose. My local dealer has offered me the bottom hose only for a mere £74 or the entire hose from the air box to the turbo for £93 including the metal section. To ease the pain (his words) he was prepared to offer a 10% discount to me. I have seen the bottom hose (not OEM) on Ebay for £28. The dealer also said he often sells a sensor (£93) on the intercooler outlet pipe at the same time when people are replacing the turbo air inlet pipes. I’ve not seen any mention of this on any of the posts that I have read. Anybody come across this one?
Any help, comments or advice on any of the above would be appreciated. I’m running out of ideas (and money) to resolve this matter to a successful conclusion.

Hello,

Just wondering, could a blocked cat cause this code?

Cheers

Rob

Edit, never mind

Thanks for this thread - it has proved invaluable!

Just recently picked up an S60 D5 on an 03 plate with 117k for 1200 quid, though on the drive home, the dreaded 'engine service required' limp mode would chime in every time I tried to take it past 2.5k rpm... The car had a new intercooler in July this year and a new pattern fuel filter, which ruled them out, but here's what I worked through:

-Top engine mount was shagged, so replaced it and at the same time changed thr turbo inlet pipe for a new pattern one. Still no change. .

-Took EGR valve pipe off and decoked it, though it wasn't too bad compared to some I've seen on here.

- Took of the turbo control valve and cleaned the tiny membrane/fiter with carb cleaner. This was completely blocked. Noticeable pick up in turbo response afterwards and engine seemed smoother, but still got limp mode at 2.5k.

I was about to give in and get the codes read, when I read somewhere else that booting it hard in 4th gear from 40mph can 'exercise' and unstick the turbo vanes... I did this several times after putting 30 quids worth of Shell V Power in it, and with each 'boot' it got higher up the rev range before the limp mode cut in. After about five goes, it then pulled cleanly up to the red line with no limp mode!

I have since given it a good shoeing in 3rd and 4th, and it seems to have cured it... It has returned a couple of times after prolonged low rpm driving around town in traffic, but then clears again once 'booted.'

In short, I plan to run a couple of tanks of V Power and some redex through it to give it achance, but the above pretty much seems to have done the job!

Hope this helps someone out in the same way the rest of this thread has done for me...!

Nick

I found on my 185hp engine that the cause was simply a loose hose clip on the turbo to the pipe beneath the engine.

A leak on the front engine mount was unrelated as the 185hp engine has an electronic servo for the turbo.

Have you sorted out the TCG readings, because I got the same results what were opposite with the Mike readings?

http://www.volvoforums.org.uk/showth...ghlight=Engine

Everyone loves photos, right? 😀

Was having a look through ebay other day and found this

http://www.ebay.co.uk/itm/Turbo-Pres...8AAOSwFnFWFTJp

Obviously listed for alfa models but is pierburg, looks to have same connector and has the white end part and is less than half the price of volvo one,

Ecm 6805
 

My V70 D5 (2003 / 117K) is suffering this problem only under load:

If I don't boot it its fine

If I do boot it goes in to limp

Everytime I turn off and restart the "Engine Service Required" is cleared along with ECM 6805.

I have so far cleaned the boost control valve (and it ran a little better)
Notice lots of gunge in the intercooler pipe I removed to do the BCV, so I also cleaned this followed closly by me.

Could this problem be vanes stuck or is an "Itallian service" required?

I too have had this code/problem, unfortunatly for me it turned out to be the turbo that was shagged, bearings completly had it and possible cracked housing as i had a lot of hissing on boost, one recon turbo off ebay and now running properly for the first time since i bought the car.

Not posted on the board for ages but will add the following;

I had this problem on an intermittent basis. Codes were read by Volvo and confirmed the ECM-6805 code.

I had engine mounts replaced, vac system tested, intercooler checked, smoke test for leaks, Alternator pulley clutch changed as it was faulty and it in itself can cause the same fault code according to the Dealer.
They obviously checked the TCV etc etc as they had the car for two days with the Service manager himself working on it as he had more experience with the 'older' Volvo's

There was nothing else to check and it was suggested the last thing would be to fit a new Turbo complete with vac actuator. This I got a quote for, 2 years ago at approx £1100 fully fitted by Volvo.

I declined at the time as all the other work I had done along with this had added up a bit and I needed some time.

The car continued to go into limp mode occasionally for a few weeks and then it decided to behave perfectly for a whole year.

I have I will note always used BP Ultimate Diesel in the car.

Anyway, just days before the next MOT I had Limp mode again three times. When the car went in for its MOT and service, Volvo said no codes were logged so there was no evidence to go on.

Had the limp mode a few times after then it has been fine again for about 8 weeks, now I have had limp again three times in the last three weeks.

So who knows. Im just settled to living with it. Its not a real problem.

Its just so random. Mine usually comes in at half throttle or so when the revs get near 3000rpm.

On occasions when I do give the car a good Italian style right foot, the problem does not occur.

To me if a turbo is sticky it will either go to limp 'every time' you boot the car or on a regular basis.

It will not do it a few times then be fine for months or a year then suddenly decide to stick again.

It done it today, but at medium throttle on the way to work. On the way home it was perfect.

Im living with it, life to short to stress over a minor annoyance.

If you are hitting 3,000 rpm then surely you are over the speed limit,I have a few issues but at 2,500 rpm I am right on the limit, interesting post though on this code, got an Autel scanner today, got 5 codes showing including this one, will have to work through them with the help of (SiRobb) !

I'm also having an issue with the dreaded ECM-6805. I only get the code when the engine is cold, never when warm. When looking at the data from VIDA, it shows that the VTN actuator opens up 100% very easily when the engine is cold, and this creates overboost. When the engine is already warm, it usually doesn't go over 80%. Has anybody had similar issues? Could it be a sticky turbo?

Well here is the weird bit.

As I previously posted, my Limp Mode is sporadic and there has never been a pattern to it, just random.

Well I have had it again today, no news there, but the weird bit is it was after leaving a particular set of traffic lights.

I have been through that set of lights about ten or twelve times over the last few months and only once did I have a fully functioning engine for the rest of the drive.
Every other time the car has gone to limp mode.

Either those lights don't like me, or there possessed , or there some electrical interference radiating from them.

Yes I have had Limp mode in other occasions from time to time but this place is getting a bit of a reputation with my car.

And no, Im not pulling away any different to any other junction along my route, this was after 30 miles of perfect driving.

Drove home tonight along a different route and all fine.

Fate, co-incidence, ghostly presence or Electro Magnetic Pulse !! Who Knows.

Well thats my strange day for you.

when i bought my xc70 it started going into limp mode everytime i booted it over 3k , i had a terraclean done but i dont really think that worked , i went on my hols over 200 miles or more at high revs in 5th , never went into 6th to just try to clear some crap out , after i got homp it never went into limp and for the last 2 weeks its been very powerful and responsive , as of last night but only when the engine has been cold its gone into limp mode 3 times now by just a medium throttle , the temp dropped last night here in sheffield to below 5deg so im wondering if theres a temp sensor or something thats my problem as its not doing it once the engine is warm.

I would imagine that the carbon deposits on the turbo vanes are harder when cold, but become softer and easier to move once the engine and turbo have warmed up.

cheers dan , i might have to do a turbo cleaner sesion again or boot it in 4th from 40 to redline untill it stops limping like ive read somwhere, im not having the turbo off to clean.

The only additive I've ever found that works is Forte Diesel Turbo cleaner. It really does make a difference, though a few applications may be needed depending on the severity of the problem. We're assuming that every other cause of ECM-6805 has been discounted, and that the fault actually is the vanes. Good long runs with frequent full range throttle movements seems to keep ECM-6805 at bay.

i have started driving it a bit more aggressive but only doing a long run every now and then isnt really doing it good , its been great for 2 weeks aswell i thought it had gone for a while , how wrong i was,,,, im off work tommorow so might give it a blast somewhere , ive got a load cover to pick up from derby so might run it in 4th to keep it red hot and hopefully clean some
crud off

has anyone bought one of these?

Hi I am shore it will work, it does look like you would have to drill the mounting holes
Dave

I've had the ECM-6805 intermittently for years on my D5, but it had now got to the point of every time you tried to overtake it would show it's ugly head.
No change with engine mount feed plugged, so no issues there.
I had previously changed the turbo control governor with a 2nd hand part, but no change.
As the 2nd hand part was potentially no better than the one on the car, I gave in and bought a new part (p/n 30637251) from Volvo last week (£ouch)... still no improvement - except one test-drive when it was faultless, but the issue was back on the next!

Previously I'd *not* changed the turbo intake pipe as my '04 car has the later pipe design which is stronger, and from my experience with other (older) D5's this causes a squeal when the pipe collapses and restricts the flow - and I had no squeal.
Anyway, I had one of these in the garage from another car I stripped for parts - which showed a 05 date code and generally looked fresher than mine.
I fitted it today (complete with the PCV heater) - and suddenly no further issues!!

So - maybe these later hoses don't screech when they collapse?! Or maybe the PCV heater was faulty and was related? Don't know - and it's early days, but hopefully that's the end of the issue anyway.

I'm temped to swap the governor back and sell the new one on ebay!