Hi all,

have collected the mod kit from volvo, but with the D5 in the 2007 S80 there is no side access to the butterfly looking from the front, you have engine casting to the right and a large alloy block to the left. Can you prise the butterfly off?


Regards


Joe

Butterfly
 

Does your swirl linkage look like the attached pic?, this was mine after fitting the volvo 'nail' kit, if you move the butterfly to where its shown thats the best access you have to make the hole in the butterfly, you cant remove the butterfly its part of the swirl flap mechanism, post a pic of yours...

pic that should be attached to prev post
 

missing pic

Hi Thassos,

no mines not like that, where you can see the cambelt cover, on mine there is a an alloy casting. I'll take a picture tomorrow with the induction pipe removed.


Joe

hopefully there will be a picture along soon......

as you can see there is now a large casing which appears to be something to do with the cooling system, there is no way to insert the pin from behind. Thankfully someone has already drilled a hole through the butterfly, now all I have to do is find a way to get the stay washer onto the end. Any ideas?

I can see your problem !
 

Thanks for posting a pic, i can see your problem now !

It looks like someone has used the volvo 'nail' kit already, but i dont know how they have fixed the far end (casting side) only idea i can think of is using some sort of suitable bonding agent to glue a pin or similar in place, and maybe make a different linkage. But you really need a stop to ensure it wont get overloaded and drop off per the usual !

Hi Thassos,
I put the nail in! There was already a hole through the butterfly because the previous dealer had bodged up some wire and solder through the arm and butterfly, however the wire had stretched and the arm was moving but the butterfly was not.
Suprisingly the nail as it is, is holding it in place, I will try over the weekend to fit the slip washers.

Joe

Hi guys been directed to here ive got a s60 d5 55 reg had the car about a week when the arm popped off the garage put it back on and orded the upgrade at the same time its lasted a few month but broke all together at the ball yesterday the bump stop seems a better fix than the volvo upgrade the indy i bought the car off used to be a volvo dealer and have been great there fixing it again for me masters of spennymoor nice garage for a change lol forgive my grammer and spelling :-( ps if it goese through cycle every 5-6 starts its going to break alot i do 2 nights a week delivering pizzas cant complain to much its the reason i can afford to run it in the first place ;-)

Swirl arm thanks
 

I got the dreaded engine system urgent message yesterday and thanks to this forum especially bic7 it is now fixed. My experience-
I found a split pin the same diameter as the hole left in the arm after the ball had broken off. I put it in a vice and, using a hammer, I flattened the head so that it would not foul the head casting. I heated it and easily passed it through the engine lever. I attached the arm, bent over the split pin and trimmed the ends with a pair of wire cutters. That took about 5 mins.
I made bic7's end stop with an elongated mount hole. I mounted it and nipped the screw up. I then operated motor without the swirl arm attached(every 5th engine stop) and allowed it to nudge the motor lever to push the end stop. I backed it off a tad and tightened it and attached the arm. This took about 10 mins. Job done.
Isn't it disgraceful that the best the mighty Volvo can do is offer a £700 repair when someone like bic7 can apply a bit of logic and see what is going wrong. There is very little resistance when the arm operates so it is obvious that something else is applying excessive force - the motor when it calibrates.
I have a code reader and this problem does not show a code. From what I read the message will go away after a few days of operating

inv never seen alloy casing like that ever before