S40 (New) Engine 2.0D : - Hes a little head scratcher for you all

dawber1990 · Jul 14th, 2014, 14:19

Ok so i have a 2005 Volvo S40 2.0 PSA diesel that keeps blowing or splitting the leak off pipes off the injectors. I have to tie wrap them on to get off the street otherwise its instant pop off under load. Running with fuel cap off.

I have replaced all leak off pipe, replaced the non-return valve that sits under the manifold, all vacuum pipes checked and tie wrapped on. Checked all pipe work back to the tank and no blockages. New fuel filter. Tried an injector additive too. I will be trying a leak off test tomorrow so i will post the results of that then. I have got new copper seals for the injectors too which i have yet to fit. Just wondering if their is anything i have overlooked or if anyone else has had the same problem.

Thanks in advance, Chris

Wooders · Jul 15th, 2014, 02:02

You replaced the metal clips on the spill pipe to injector?

mattievrs · Jul 15th, 2014, 09:32

Could be the fuel pressure regulator sensor or even the fuel pump that are playing up with excessive pressure? Unlikely though.

dawber1990 · Jul 15th, 2014, 18:29

Thanks for the replies guys! Wooders i have not replaced them but i have made sure they are tight as can be. never had them pop the clips out though just the rubber pipes that they connect to. Been to firth diesel injectors today and had the injectors tested and all injectors are working fine. Out of curiosity i had a look inside the fuel filter and found little bits of metal filings at the bottom. As you say Mattie my thoughts are that it is now the fuel pump. Stranger things have happened i guess. Ha. Can anyone recommend a place to get one or in fact shed anymore light on this problem? Cheers

Guru · Jul 15th, 2014, 21:50

The wise thing to do would be to go in and have your codes read, both fuel pressure and it's volume are intensely monitored in the 2.0D and any fluctuations surely would have logged an ECM error code.

There are 2 solenoids on the high pressure fuel pump, one controls fuel volume, the other controls fuel pressure, only a diagnostic machine can tell you which one of them is at fault
.. I still however suspect a blockage somewhere en-route back to the tank, but you did say that you've omitted this possibility .. problem is, any fault arising at the level of the fuel pump would throw you into limp mode the minute you accelerate ..

Btw., I wouldn't worry too much about those metal particles found in the fuel filter cup, it doesn't necessarily mean a broken fuel pump .. after being a member of four Volvo forums in four different languages through out the years of 2.0D ownership I would say that it's a very common finding.

p.s. these high pressure Siemens VDO fuel pumps cost around 1k bought new.

dawber1990 · Jul 16th, 2014, 08:35

Sorry Guru forgot to mention i have had it plugged in at least 6 times. ha. only had one recurring code and that was something about the EGR, but i have had a EGR and DPF delete done on so i was never fussed about it. this tells me its something mechanical and not electrical. like the pump is failing but not failed. i can not stress enough that they are no blockages on the return from the back of the injectors to the tank. what are those filings then? first iv seen them. ha. i found a website that will supply a reconditioned one for £325 with a 12 month warranty. its looking like my best option to me. convince me otherwise, PLEASE. ha

Guru · Jul 16th, 2014, 23:52

Well, as your title states, this really is a head scratcher .. and since you've had it plugged in 6 times and the record remained clean, then it can only be mechanical, the thing is I just can't imagine the pump building up enough pressure to make the return lines split off; that without even triggering an alarm at the fuel pressure sensor on the fuel rail itself .. but hey ho I'm no expert and surely not a diesel expert but I'll be interested in knowing what was causing this and how it gets solved when it gets solved.

btw., I'd check the functionality of that component in bold type above before buying things.. just saying

cheshired5 · Jul 17th, 2014, 04:17

A video of these erupting leak off pipes would be helpful (and interesting).

dawber1990 · Jul 17th, 2014, 18:26

It really is baffling. ha. If the fuel pressure sensor isn't working surely that would log a code when i have had it plugged in? they hasn't been a change in how the car drives either. just that the spill pipes go POP every now and again. Im no expert either that is why im asking here for help. hopefully we can solve this mystery together. the thing is Cheshired5 it only does it under load. i can sit and rev the knackers off it and maybe get a little weep. its when on the move it does it. i have no indication til i stop and smell the diesel. If i drive very, VERY steady i can get about. Say change gear at 1500rpm. ha. Maybe thats a clue but i dont know.

cheshired5 · Jul 17th, 2014, 18:47

So they ALL pop off in one go or are some more prone than others?
Have you done a leak back test?
If you have, what were the volumes returned?

Jul 14th, 2014, 14:19	#1
dawber1990 New Member Last Online: Jan 18th, 2015 17:23 Join Date: Feb 2014 Location: Barnsley	Hes a little head scratcher for you all Ok so i have a 2005 Volvo S40 2.0 PSA diesel that keeps blowing or splitting the leak off pipes off the injectors. I have to tie wrap them on to get off the street otherwise its instant pop off under load. Running with fuel cap off. I have replaced all leak off pipe, replaced the non-return valve that sits under the manifold, all vacuum pipes checked and tie wrapped on. Checked all pipe work back to the tank and no blockages. New fuel filter. Tried an injector additive too. I will be trying a leak off test tomorrow so i will post the results of that then. I have got new copper seals for the injectors too which i have yet to fit. Just wondering if their is anything i have overlooked or if anyone else has had the same problem. Thanks in advance, Chris

Jul 15th, 2014, 21:50	#5
Guru Premier Member Last Online: Oct 25th, 2023 07:46 Join Date: Feb 2009 Location: Between chair and keyboard	The wise thing to do would be to go in and have your codes read, both fuel pressure and it's volume are intensely monitored in the 2.0D and any fluctuations surely would have logged an ECM error code. There are 2 solenoids on the high pressure fuel pump, one controls fuel volume, the other controls fuel pressure, only a diagnostic machine can tell you which one of them is at fault .. I still however suspect a blockage somewhere en-route back to the tank, but you did say that you've omitted this possibility .. problem is, any fault arising at the level of the fuel pump would throw you into limp mode the minute you accelerate .. Btw., I wouldn't worry too much about those metal particles found in the fuel filter cup, it doesn't necessarily mean a broken fuel pump .. after being a member of four Volvo forums in four different languages through out the years of 2.0D ownership I would say that it's a very common finding. p.s. these high pressure Siemens VDO fuel pumps cost around 1k bought new. __________________ Volvo S40 2.0D momentum \| 100kw/136bph \| 2005 \| Euro III \| 49mpg \| Electric silver

Jul 16th, 2014, 23:52	#7
Guru Premier Member Last Online: Oct 25th, 2023 07:46 Join Date: Feb 2009 Location: Between chair and keyboard	Well, as your title states, this really is a head scratcher .. and since you've had it plugged in 6 times and the record remained clean, then it can only be mechanical, the thing is I just can't imagine the pump building up enough pressure to make the return lines split off; that without even triggering an alarm at the fuel pressure sensor on the fuel rail itself .. but hey ho I'm no expert and surely not a diesel expert but I'll be interested in knowing what was causing this and how it gets solved when it gets solved. btw., I'd check the functionality of that component in bold type above before buying things.. just saying __________________ Volvo S40 2.0D momentum \| 100kw/136bph \| 2005 \| Euro III \| 49mpg \| Electric silver

Jul 17th, 2014, 04:17	#8
cheshired5 Premier Member Last Online: Dec 26th, 2021 13:42 Join Date: Dec 2013 Location: Crewe	A video of these erupting leak off pipes would be helpful (and interesting). __________________ 2002 S60 SE D5 Manual 209000 miles

Jul 17th, 2014, 18:47	#10
cheshired5 Premier Member Last Online: Dec 26th, 2021 13:42 Join Date: Dec 2013 Location: Crewe	So they ALL pop off in one go or are some more prone than others? Have you done a leak back test? If you have, what were the volumes returned? __________________ 2002 S60 SE D5 Manual 209000 miles

Jul 15th, 2014, 02:02	#2
Wooders Member Last Online: May 13th, 2021 07:54 Join Date: Jan 2012 Location: Cumbernauld	You replaced the metal clips on the spill pipe to injector?

Jul 15th, 2014, 09:32	#3
mattievrs Master Member Last Online: Sep 3rd, 2020 12:03 Join Date: Mar 2013 Location: Leicester	Could be the fuel pressure regulator sensor or even the fuel pump that are playing up with excessive pressure? Unlikely though.

Jul 15th, 2014, 18:29	#4
dawber1990 New Member Last Online: Jan 18th, 2015 17:23 Join Date: Feb 2014 Location: Barnsley	Thanks for the replies guys! Wooders i have not replaced them but i have made sure they are tight as can be. never had them pop the clips out though just the rubber pipes that they connect to. Been to firth diesel injectors today and had the injectors tested and all injectors are working fine. Out of curiosity i had a look inside the fuel filter and found little bits of metal filings at the bottom. As you say Mattie my thoughts are that it is now the fuel pump. Stranger things have happened i guess. Ha. Can anyone recommend a place to get one or in fact shed anymore light on this problem? Cheers

Jul 16th, 2014, 08:35	#6
dawber1990 New Member Last Online: Jan 18th, 2015 17:23 Join Date: Feb 2014 Location: Barnsley	Sorry Guru forgot to mention i have had it plugged in at least 6 times. ha. only had one recurring code and that was something about the EGR, but i have had a EGR and DPF delete done on so i was never fussed about it. this tells me its something mechanical and not electrical. like the pump is failing but not failed. i can not stress enough that they are no blockages on the return from the back of the injectors to the tank. what are those filings then? first iv seen them. ha. i found a website that will supply a reconditioned one for £325 with a 12 month warranty. its looking like my best option to me. convince me otherwise, PLEASE. ha

Jul 17th, 2014, 18:26	#9
dawber1990 New Member Last Online: Jan 18th, 2015 17:23 Join Date: Feb 2014 Location: Barnsley	It really is baffling. ha. If the fuel pressure sensor isn't working surely that would log a code when i have had it plugged in? they hasn't been a change in how the car drives either. just that the spill pipes go POP every now and again. Im no expert either that is why im asking here for help. hopefully we can solve this mystery together. the thing is Cheshired5 it only does it under load. i can sit and rev the knackers off it and maybe get a little weep. its when on the move it does it. i have no indication til i stop and smell the diesel. If i drive very, VERY steady i can get about. Say change gear at 1500rpm. ha. Maybe thats a clue but i dont know.

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