V50 General : - 1.6 DrivE Injector replacement

sunstriker · Aug 13th, 2023, 20:54

Hi guys,

I just registered to this forum as a fresh proud owner of a Volvo V50 D2 (D4162T) 1.6D with 120000 km on the clock. I already checked similar forums like Swedespeed and the dutch volvo-forum, as I am from Belgium. However I could not find an answer but I did end up here on an older archived article.

This car drives pretty well but it did fail emissions test this year with over 1 million particles (the limit is 250k). I thought it was a failed DPF at first. But after scanning the car 3 error codes popped up: Injector 1, 2 and 4 - offset learning at maximum limit. Injector 3 failed a few years ago and was replaced by the dealer 45000 km ago. The car idles with noticeable vibrations, at least this is what I think, I've never driven the vehicle when it was new. It also doesn't like to do slow speeds in 2nd gear where it seems to stall, then the rpm pops back up, so it 'shocks' a lot. However at higher speeds everything is just fine. Also fuel consumption didn't change (previous owner is my dad and he told me).

According to the dealer this is all connected and I tend to agree. At low RPM too much fuel is injected into the cilinders 1, 2 and 4 because the injectors are worn, making the engine run rich, producing soot and low power at low revs. As the new emissions test is done at idle this makes sense to me.

However I'm looking for confirmation on this as I want to do this job myself (except for the coding of the injectors) and want to have a reasonable chance of fixing this issue by buying 3 new injectors. They cost about €240 (sorry, euro) from the cheapest brand I could find (VDO). Economically this car is pretty written off as diesel euro 5 are not welcome anymore in large cities within 2 years.

I did put in some Wynn's Injector cleaner and the car drove much better until the product was out of the fuel. Errors came back a week or so later... I also read that the fuel filter could be to blame but this was replaced by the dealer last year about 5000 km ago. The car always drove about 50 km of highway every workday until my dad retired. Then it only drove about 15 km every week, no highway.

I read everywhere that this engine (also used in Ford etc) has an injector weak spot but I don't find many issues like mine online, hope someone can help me.

Teddy1975 · Aug 14th, 2023, 05:36

You should be able to find remanufactured Bosch injectors for less than 240 € instead of buying new. Sorry, I can't offer more help on the matter than this.

sunstriker · Aug 14th, 2023, 10:19

Thanks Teddy. I do find second hand injectors but given the reputation of this engine I'm not sure it that's a good bed. Lowest mileage of donor vehicles I can find is about 90k km. I find some shops that sell reconditioned ones but mostly in the UK, which is not so interesting anymore to import from.

Teddy1975 · Aug 14th, 2023, 11:55

If there are any independent garages near you, try to visit one of them and ask if they can order reconditioned injectors for your car and what that would cost. Garages often have access to parts suppliers not accessible to us end users.

I wouldn't buy used injectors either, but reconditioned ones are mechanically as good as new, only cheaper.

sunstriker · Aug 14th, 2023, 15:33

Well instead I've found two businesses in the neighbourhood that specialise in injectors and DPF's. I contacted them (it's a holiday here tomorrow) through mail to see how they can help. supply me with revised parts or maybe testing/cleaning/revising my current injectors.

Holdie · Jan 5th, 2024, 17:54

Hi

Please see my post of today (05.01.24) which touches on similar issues to those you raised.

Did you ever get a diagnosis of the injector problem and sort it out?

Just curious to know as I'm going to have to get my vehicle into the garage to try and resolve the lumpy engine and exhaust smoking, so it may be that any issues / solutions you identified may prove helpful to me.

Thanks

sunstriker · Jan 5th, 2024, 22:47

Yeah, I got new injectors in the end. But I'm still dealing with a faulty DPF. But the car drives much better now.

Quote:

Originally Posted by Holdie

Hi

Please see my post of today (05.01.24) which touches on similar issues to those you raised.

Did you ever get a diagnosis of the injector problem and sort it out?

Just curious to know as I'm going to have to get my vehicle into the garage to try and resolve the lumpy engine and exhaust smoking, so it may be that any issues / solutions you identified may prove helpful to me.

Thanks

Clan · Jan 5th, 2024, 23:40

Quote:

Originally Posted by sunstriker

Yeah, I got new injectors in the end. But I'm still dealing with a faulty DPF. But the car drives much better now.

Were the injector codes programmed into the ECU with the new values supplied with the injectors? There was a software upgrade around 2013 which allows the injectors to self trim themselves more effectively. Always a good idea to have the latest ECU software anyway.

sunstriker · Jan 6th, 2024, 17:07

This car was maintained every year by the Volvo dealer until 2022 so I guess it got the latest upgrades. But yes, the injectors were coded to the ECU with the values provided. I used Vdash to do this.
I'm not sure how the ECU will adapt without the correct values though. The old injectors had a fault code 'offset too high', so the ECU telling me it couldn't adapt the values any further. I'm not sure if this scenario can happen if you don't code them. It seems to me the ECU is kind of flexible but after spending €600 on 3 new injectors (1 of them was already replaced a while ago) €25 on Vdash to code them correctly seemed like the right way to do it.
I had the injectors tested and I got back a graph with the range in which they are supposed to work (amount of fuel for a given pressure and a give pulse). One was just failing and 2 other were really at the bottom of the curve...

Clan · Jan 6th, 2024, 23:36

Quote:

Originally Posted by sunstriker

This car was maintained every year by the Volvo dealer until 2022 so I guess it got the latest upgrades. But yes, the injectors were coded to the ECU with the values provided. I used Vdash to do this.
I'm not sure how the ECU will adapt without the correct values though. The old injectors had a fault code 'offset too high', so the ECU telling me it couldn't adapt the values any further. I'm not sure if this scenario can happen if you don't code them. It seems to me the ECU is kind of flexible but after spending €600 on 3 new injectors (1 of them was already replaced a while ago) €25 on Vdash to code them correctly seemed like the right way to do it.
I had the injectors tested and I got back a graph with the range in which they are supposed to work (amount of fuel for a given pressure and a give pulse). One was just failing and 2 other were really at the bottom of the curve...

That part of the job should be ok then 👍

Aug 13th, 2023, 20:54	#1
sunstriker New Member Last Online: Mar 7th, 2024 13:32 Join Date: Aug 2023 Location: Antwerp	1.6 DrivE Injector replacement Hi guys, I just registered to this forum as a fresh proud owner of a Volvo V50 D2 (D4162T) 1.6D with 120000 km on the clock. I already checked similar forums like Swedespeed and the dutch volvo-forum, as I am from Belgium. However I could not find an answer but I did end up here on an older archived article. This car drives pretty well but it did fail emissions test this year with over 1 million particles (the limit is 250k). I thought it was a failed DPF at first. But after scanning the car 3 error codes popped up: Injector 1, 2 and 4 - offset learning at maximum limit. Injector 3 failed a few years ago and was replaced by the dealer 45000 km ago. The car idles with noticeable vibrations, at least this is what I think, I've never driven the vehicle when it was new. It also doesn't like to do slow speeds in 2nd gear where it seems to stall, then the rpm pops back up, so it 'shocks' a lot. However at higher speeds everything is just fine. Also fuel consumption didn't change (previous owner is my dad and he told me). According to the dealer this is all connected and I tend to agree. At low RPM too much fuel is injected into the cilinders 1, 2 and 4 because the injectors are worn, making the engine run rich, producing soot and low power at low revs. As the new emissions test is done at idle this makes sense to me. However I'm looking for confirmation on this as I want to do this job myself (except for the coding of the injectors) and want to have a reasonable chance of fixing this issue by buying 3 new injectors. They cost about €240 (sorry, euro) from the cheapest brand I could find (VDO). Economically this car is pretty written off as diesel euro 5 are not welcome anymore in large cities within 2 years. I did put in some Wynn's Injector cleaner and the car drove much better until the product was out of the fuel. Errors came back a week or so later... I also read that the fuel filter could be to blame but this was replaced by the dealer last year about 5000 km ago. The car always drove about 50 km of highway every workday until my dad retired. Then it only drove about 15 km every week, no highway. I read everywhere that this engine (also used in Ford etc) has an injector weak spot but I don't find many issues like mine online, hope someone can help me. Last edited by sunstriker; Aug 13th, 2023 at 20:56.

Jan 5th, 2024, 17:54	#6
Holdie New Member Last Online: Jan 8th, 2024 20:40 Join Date: May 2020 Location: Norwich	1.6 DrivE Injector replacement Hi Please see my post of today (05.01.24) which touches on similar issues to those you raised. Did you ever get a diagnosis of the injector problem and sort it out? Just curious to know as I'm going to have to get my vehicle into the garage to try and resolve the lumpy engine and exhaust smoking, so it may be that any issues / solutions you identified may prove helpful to me. Thanks

Aug 14th, 2023, 05:36	#2
Teddy1975 Member Last Online: Today 05:54 Join Date: Aug 2017 Location: Denmark	You should be able to find remanufactured Bosch injectors for less than 240 € instead of buying new. Sorry, I can't offer more help on the matter than this.

Aug 14th, 2023, 10:19	#3
sunstriker New Member Last Online: Mar 7th, 2024 13:32 Join Date: Aug 2023 Location: Antwerp	Thanks Teddy. I do find second hand injectors but given the reputation of this engine I'm not sure it that's a good bed. Lowest mileage of donor vehicles I can find is about 90k km. I find some shops that sell reconditioned ones but mostly in the UK, which is not so interesting anymore to import from.

Aug 14th, 2023, 11:55	#4
Teddy1975 Member Last Online: Today 05:54 Join Date: Aug 2017 Location: Denmark	If there are any independent garages near you, try to visit one of them and ask if they can order reconditioned injectors for your car and what that would cost. Garages often have access to parts suppliers not accessible to us end users. I wouldn't buy used injectors either, but reconditioned ones are mechanically as good as new, only cheaper.

Aug 14th, 2023, 15:33	#5
sunstriker New Member Last Online: Mar 7th, 2024 13:32 Join Date: Aug 2023 Location: Antwerp	Well instead I've found two businesses in the neighbourhood that specialise in injectors and DPF's. I contacted them (it's a holiday here tomorrow) through mail to see how they can help. supply me with revised parts or maybe testing/cleaning/revising my current injectors.

Jan 6th, 2024, 17:07	#9
sunstriker New Member Last Online: Mar 7th, 2024 13:32 Join Date: Aug 2023 Location: Antwerp	This car was maintained every year by the Volvo dealer until 2022 so I guess it got the latest upgrades. But yes, the injectors were coded to the ECU with the values provided. I used Vdash to do this. I'm not sure how the ECU will adapt without the correct values though. The old injectors had a fault code 'offset too high', so the ECU telling me it couldn't adapt the values any further. I'm not sure if this scenario can happen if you don't code them. It seems to me the ECU is kind of flexible but after spending €600 on 3 new injectors (1 of them was already replaced a while ago) €25 on Vdash to code them correctly seemed like the right way to do it. I had the injectors tested and I got back a graph with the range in which they are supposed to work (amount of fuel for a given pressure and a give pulse). One was just failing and 2 other were really at the bottom of the curve...

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)