Engine: D5: Engine going into limp under load

[357kurt]

VOLVO V70 2.4 D5 D5244T 2401CC 120KW 10-01 t/m 06-04

Mileage:110K

The problem is as such :

The car has not been driven for 2-3 months when I bought the car, the car had gone w/o service for 40000km, nothing too scary. I gave it the following

Maintenance :

-changed timing belt
-changed all filters & oil (also fuel filter)
-new tires, brake pads, wheel bearing

History :

Full service maintenance, nothing serious, in fact normal maintenance only! 1st owner car by Lease company

Symptons :

Now the engine dies under throttle especially under the following circumstances :

*120-130kmh partial load acceleration
*rolling start full throttle (at ~4000rpm dies)

Course of action :

Fault codes 1:
*2313: Volvo 08979 injection valve 3 malfunction Intermittent
*1200: Volvo 04608 inlet air temperature sensor : value not plausible
*1300: Volvo 04864 Mass airflow sensor circuitinvalid signal permanent

*Changed air flow meter
*Testdrive
->Problem remained

After consulting a diesel center which are experts on diesel cars (also do a lot of work for dealers) we decided to put in overhauled injectors since the original ones were still in.

*changed injectors
*Testdrive
-> problem remained!!

Fault codes 2:
*2313: Volvo 08979 injection valve 3 malfunction Intermittent
*2503: Volvo 09473 fuel rail/system pressure- too high intermittent

At this stage I decided to bring the car to the diesel center, the car has been under their attention since a week almost!

They replaced :

*ECM
*Fuel pressure sensors
*Checked all engine wiring

I've also informed at one of the largest Volvo dealers , they said it might be a problem with the pump in the fuel tank?

Any input on this problem would be really appreciated!!

[357kurt]

p.s. can one of the moderators move this topic to the new models v70? tnx

[Chris_Rogers]

I'm puzzled B5244S is a petrol engine type code and you are taking it to a diesel specialist?

That year is the car and what engine is actually fitted?

[357kurt]

edit!

30-08-2002 registered

tnx

[357kurt]

Problem found :

Using Bosch Car Service and their diagnostic tools we found that injector #3 uses too much voltage (i.o.w. stays open too long) ,we found this comparing scope images from all 5 cilinders.

Replaced the ECU (motormanagent computer) for a new unit, costs : ~900Euro.(735+33 codes ex VAT) From different sources we learned that it is impossible to switch ECU from another D5. Also I found difference in pricing of the ECU. As far as I know all dealers in a country should have the same pricing..weird..

Problem solved, this is good information , has costed me a lot of money to come this far. (not to mention - bad diagnostic from a firm that call themselves "diesel specialists" )

[GED-S60]

hi kurt you have my sympathy,i know what its like to keep throwing money at a problem,and it never seems to cure it ,,,can you tell me why you cant swap an ecu from another d5 to yours,,

[357kurt]

This is what I find strange as well, I always thought BOSCH ECU's are reprogrammable but 3 dealers and (trustfull) sources told me it could not be done since some parameters can only be programmed once (to prevent ECU's beeing stolen etc.) Maybe there is a difference in UK and Australian models (mainland Europe).

Anyway the ECU cannot be delivered untill may 23rd , so I took the ECU to a repair shop (www.actronics.nl) ,they are not familiar with this type of ECU but they will try and repair it. Very good firm, have had many gauges and Mitsubishi air control valves fixed.

I will keep progress posted

[GED-S60]

keep us informed as to what happens this may be a piece of valuble info

[357kurt]

I just heared that they could not find anything out of the ordinary at the repair shop, back to square one..

Starting to think best solution is a piece of clotch , gasoline and a lighter