Desperate for Help S60 D5 6805 fault
 

Where to begin - My 2003 S60 D5 has fault 6805

Been to volvo - who diagnosed waste gate problem - supposedly fixed it - but fault remained.

Been to diesel specialist who replaced turbo - supposedly fixed it - but fault remains.

Changed fuel filter - fault remains!

Currently with diagnostic specialist - who thought problem was with vac system and engine mounts (which are not in great condition) has disconnected vac pipe for now thinking it would prove fault - but fault remains!

Basically the car is great up to 60 mph - in town behaves with no faults. Fault "Engine Service Required" displays when motoring on motorway (usually on an incline on ramp or actually on motorway at 60+ mph) but always following acceleration. Think overtaking 70-80 mph car "limp modes" with no turbo. If you continue to drive the fault will clear the turbo will kick in and you can drive off!!!

Any suggestions welcome......

Am getting desperate now as I have spent a lot of money getting nowhere quite literally - do not want to continue driving car without turbo to get out of situations

ggggggggggggggrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr :)

where did the "New" turbo come from? The volvo replacement is specificaly calibrated to suit the D5 and has to be right . A General purpose turbo that " will fit" might not be suitable . The air flow is critical .

I drew up this chart a long time ago , it may guide you a bit ...

will take this to the garage when i return my car later this week - many thanks - am sure it will make sense to them - only makes a little bit of sense to me. am sure by the end of this I will know a damn sight more though ;-)

ECM 6805 can be easy or hard to find but you need the correct tools to do the job,
mitty vac .
vac gauge
leak off test kit
all the above can assist in helping you in the right direction. good luck
and welcome to the forum:thumbs_up:
mike

I would ask for a partial refund from the garages which attempted to fix the problem and failed...

There are quite a few thing which might cause the problem.

Start from the simple things:
1. Check the intake hose going into the turbo if it's no too soft. Have a search on the forum.
2. Replace the fuel filter if you've never done it.
3. Inspect vacuum hoses.
4. Check if the turbo VNT arm is moving - again search in the forum.
5. Clean EGR mixer - search the forum.

Does the car smoke when you go uphill or rev it when the error is triggered?
Do you hear an excessive air hissing when you drive the car harder?
Does the engine RPM increases smoothly when you accelerate?

Matt

engine fault
 

i had this for a while exactly the same
on the front of the engine on rhs there is a big intercooler pipe, looks like a big water pipe, it connects to a aluminium block and another pipe comes off and goes to turbo around rhs of engine
carefully take off pipe and see if the housing is blocked with black gunk and the pipe as well, its very messy it needs cleaning out fully
also i had same , and changed the fuel filter
hope it helps , its a diy job

I think that they may have fixed it by now as it was 6 years ago,
Dave