2002 V40 1.9TD - refusing to start
 

Hi everyone.

Before i start: sorry for my bad explanation, if you don't understand or need more info, ask and I will try to be more precise.

I have a Volvo V40 2002 1.9 diesel with engine code 'D4192T4'.
The other day I was cruising in 100km/t and suddenly I lost all engine power for 1-2 second. It came back just as quickly as it disappeared. 3-4 minutes later the same happened. From there everything was fine. I drove on for 30 minutes and stopped at a gas station for a cup of coffee. Before this I have had no problems with the car.

When I got back in the car, it refuses to start. I had a look in the engine compartment and found this:
https://lh3.googleusercontent.com/aJ...=w807-h1075-no

Some fresh oil around the EGR-valve. This can't have been there for very long, as i replaced the brake master cylinder ~2 months ago and I would have spotted this then. I could also wiggle the EGR a 1-2mm each way, though this was very strange, but if this is broken in any way it shouldn't make the car stop totally?

We also found a broken vacuum hose that was located on a small plastic thingy (that is located where the man has his arm with the watch on, and I am pointing on where the EGR-valve is located)

https://scontent-arn2-1.xx.fbcdn.net...6c&oe=57B3D1CD

Reparing the vacuum did not help, the car just chimes(?) with no attempts to start. From my recollection, I can not remembering hearing the diesel pump starting.. But I can't say that totally sure. If the diesel pump did die on the highway I would have stopped much earlier, so I don't think it's dead, more likely that it's the ECU that don't start it?

I'm thinking it could be a valve/crank-sensor or something that could be broken, and maybe I should buy a diagnostic tool and start with that.

Any ideas on where to start?

Any suggestions are very much appreciated!

Fuel starvation? Start at the source - see here.

Sounds like fuel filter OR one of the 2 O rings with it. It should be checked every oil change and changed every 20K km.

i know its doubtful but just check fuse 17(15amp) in engine bay

Some half burnt diesel residue is normal around the EGR area and it does look like oil. Oddly enough it is probably not from some dipstick using the wrong gasket, but from the intake O ring. When the EGR is cleaned both the EGR metal crush gasket and the intake O ring should be changed.

Trying seeing if it will start after the priming bulb next to the fuel filter (Under the fuse box) has been pumped until the bulb goes solid. If it does start OK the engine was sucking air in from an empty tank or one of the 2 fuel filter bowl O rings that very few dealers or garages ever bother to change.

Thank you guys for all the suggestions. I don't have the car at my place at the moment, (I live in the middle of town and my father has a small farm with good place to stay/work and most of the tools I will need) but will try to locate the problem start of next week.

Will update then :)

Btw: Was researching diagnostic tools and I found 2 types.. 1 'generic' type that takes all kind of cars from '96 and up and 1 kind that is specific for Volvo, but it seems that it only works for V40 from 2004 and up?
What is the best to do here? Buy the generic one and hope it works?

If you have an android phone (think Iphone to)than Torque app is good Buy it not the free one £3.80, you get more. A Blue tooth adapter is £5 and if it works on yours you can clear EML's and read fault codes.

I think 2002 is borderline for generic code readers. I think they brought in compatibility from 2003 onwards for the diesels.

So a generic reader may not work at all. Best to borrow one if you can and try it.

To be clear, the engine rotates but does not start?

Any warning lights on the dash?

My cheap ELM327 reader wouldn't work with my February 2002 diesel, but works fine with my September 2004 car. For the sake of less than £2.50 delivered for a reader from eBay it might be worth a try though...

Bah, looks like you where right. The generic one did not work :(
The worst is that the shop refuses to refund used diagnostic tools - £50 wasted, the volvo brand specific one costs £100, maybe that what I need.