XC90 D5 Swirl Flap Issue with Popping Noise

zakmuh · Nov 3rd, 2021, 20:26

Hi

My engine, with 200k mileage, gives this loud popping noise, mostly in cold start and intermittently when hot. I've been trying to find the cause of this issue for last 3 years and finally spotted the location. It's coming through the intake manifold. When I closed the swirl flap manually, the noise reduced significantly. Swirl flap actuating lever is bit stiff but will move both ways to its max limit.

When I opened the oil filler cap, noise is not coming through that, though its connected to the manifold.

Could this noise coming cos of the faulty swirl flap (carbon built up and not closing properly or flaps broken?)

Stuck or broken intake valves?)

Faulty injectors?)

Faulty glow plugs?)

Could it be due to clogged oil separator (crankcase ventilation)?

Could it be something else?

Cheers

zakmuh · Nov 4th, 2021, 10:14

Any thoughts?

gmonag · Nov 4th, 2021, 11:44

Could be leaking engine mounts, or some other vacuum system leak.

See sirobb's video (cheshired5)

https://www.youtube.com/watch?v=QHLy...channel=SiRobb

SwissXC90 · Nov 4th, 2021, 12:18

You can also pop off the intake hoses going into the manifold and observe how much tar and soot buildup you have.

If you see enough to alarm you, then removing and cleaning / refurbishing the entire intake manifold, including swirl flaps, intake system and EGR would be worth while doing.

zakmuh · Nov 4th, 2021, 17:29

Thanks for your replies

Yeah...thats my first port of call. Its got half an inch for carbon build up, So I'll see if this noise goes away after a through cleaning.

gmong, I don't have any noise coming through the oil filler cap as shown in Sirbob's video. I've also checked all vacuum pump and vacuum related connections.

I'll keep you all posted

Ta

zakmuh · Nov 4th, 2021, 17:31

FYI....Ive taken a video to show where the noise is coming from:

https://www.youtube.com/watch?v=q4BJiXVvDpo

zakmuh · Nov 29th, 2021, 13:40

An update...

I disconnected the injectors one at a time to check for faulty injectors, and then swapped the position of two injectors and repeated the test again-noise was consistent for each one. So this eliminates injectors.

I then disconnected the fuel pump and cranked the engine. Then it gave the popping noise from one of the cylinders. It could be that exhaust valve not opening fully. At the end of exhaust stroke there is still a little pressure when the exhaust valve closes. This pressure pops out when the intake valve opens

I have to to check rockers and lifters now then

zakmuh · Dec 9th, 2021, 18:28

Hi

Another serious update....

I've got a serious problem. On the exhaust side, one in the pair of 5th cylinder lifters is broken and it has sheared off the lifter hole - yellow arrow in the pic. Red arrow one is the good one in that pair. So that exhaust valve is closed permanently

I searched for the broken pieces in the entire area, including intake side but no single piece was found! I have to replace the cylinder head.

xc90 Broken lifter sink.jpg

Frenchguy · Apr 3rd, 2022, 11:18

Hi will the noise increase when accelerating?

Davezj · Apr 11th, 2022, 21:48

Unforyunately if you have cracked off parts the head casting that holds the liters in place in my experience it is a new head required.

but i dont think that is the source of you poping noise.
the popping is probaly just a vacuum leak.

Nov 3rd, 2021, 20:26	#1
zakmuh Junior Member Last Online: Apr 25th, 2022 11:15 Join Date: May 2016 Location: Nottingham	XC90 D5 Swirl Flap Issue with Popping Noise Hi My engine, with 200k mileage, gives this loud popping noise, mostly in cold start and intermittently when hot. I've been trying to find the cause of this issue for last 3 years and finally spotted the location. It's coming through the intake manifold. When I closed the swirl flap manually, the noise reduced significantly. Swirl flap actuating lever is bit stiff but will move both ways to its max limit. When I opened the oil filler cap, noise is not coming through that, though its connected to the manifold. Could this noise coming cos of the faulty swirl flap (carbon built up and not closing properly or flaps broken?) Stuck or broken intake valves?) Faulty injectors?) Faulty glow plugs?) Could it be due to clogged oil separator (crankcase ventilation)? Could it be something else? Cheers __________________ 2007 (Mk I) Volvo XC90 SE 2.4D D5 - 199,617 miles. Silver, black leather interior. Last edited by zakmuh; Nov 3rd, 2021 at 21:36.

Nov 4th, 2021, 10:14	#2
zakmuh Junior Member Last Online: Apr 25th, 2022 11:15 Join Date: May 2016 Location: Nottingham	Any thoughts? __________________ 2007 (Mk I) Volvo XC90 SE 2.4D D5 - 199,617 miles. Silver, black leather interior.

Nov 4th, 2021, 11:44	#3
gmonag Premier Member Last Online: Jan 15th, 2024 17:24 Join Date: Jun 2010 Location: Bury St Edmunds	Could be leaking engine mounts, or some other vacuum system leak. See sirobb's video (cheshired5) https://www.youtube.com/watch?v=QHLy...channel=SiRobb __________________ Greg

Nov 4th, 2021, 12:18	#4
SwissXC90 Premier Member Last Online: Mar 20th, 2024 18:26 Join Date: Jan 2016 Location: Cross Country	You can also pop off the intake hoses going into the manifold and observe how much tar and soot buildup you have. If you see enough to alarm you, then removing and cleaning / refurbishing the entire intake manifold, including swirl flaps, intake system and EGR would be worth while doing. __________________ XC90 R-Design MY2009, Black Sapphire Metallic. HP-Sound, RSE, Nav, Tel, ParkingCam, BLIS, ParkingHeater, RestHeat, Removable Towbar, Summer: CRATUS 20x8 on Pirelli Scorpion Zeros 255/45, Winter: NEPTUNE 17x7 on Continental WinterContact 4x4 235/65.

Nov 4th, 2021, 17:29	#5
zakmuh Junior Member Last Online: Apr 25th, 2022 11:15 Join Date: May 2016 Location: Nottingham	Thanks for your replies Yeah...thats my first port of call. Its got half an inch for carbon build up, So I'll see if this noise goes away after a through cleaning. gmong, I don't have any noise coming through the oil filler cap as shown in Sirbob's video. I've also checked all vacuum pump and vacuum related connections. I'll keep you all posted Ta __________________ 2007 (Mk I) Volvo XC90 SE 2.4D D5 - 199,617 miles. Silver, black leather interior.

Nov 4th, 2021, 17:31	#6
zakmuh Junior Member Last Online: Apr 25th, 2022 11:15 Join Date: May 2016 Location: Nottingham	FYI....Ive taken a video to show where the noise is coming from: https://www.youtube.com/watch?v=q4BJiXVvDpo __________________ 2007 (Mk I) Volvo XC90 SE 2.4D D5 - 199,617 miles. Silver, black leather interior.

Nov 29th, 2021, 13:40	#7
zakmuh Junior Member Last Online: Apr 25th, 2022 11:15 Join Date: May 2016 Location: Nottingham	An update... I disconnected the injectors one at a time to check for faulty injectors, and then swapped the position of two injectors and repeated the test again-noise was consistent for each one. So this eliminates injectors. I then disconnected the fuel pump and cranked the engine. Then it gave the popping noise from one of the cylinders. It could be that exhaust valve not opening fully. At the end of exhaust stroke there is still a little pressure when the exhaust valve closes. This pressure pops out when the intake valve opens I have to to check rockers and lifters now then __________________ 2007 (Mk I) Volvo XC90 SE 2.4D D5 - 199,617 miles. Silver, black leather interior.

Dec 9th, 2021, 18:28	#8
zakmuh Junior Member Last Online: Apr 25th, 2022 11:15 Join Date: May 2016 Location: Nottingham	Hi Another serious update.... I've got a serious problem. On the exhaust side, one in the pair of 5th cylinder lifters is broken and it has sheared off the lifter hole - yellow arrow in the pic. Red arrow one is the good one in that pair. So that exhaust valve is closed permanently I searched for the broken pieces in the entire area, including intake side but no single piece was found! I have to replace the cylinder head. xc90 Broken lifter sink.jpg __________________ 2007 (Mk I) Volvo XC90 SE 2.4D D5 - 199,617 miles. Silver, black leather interior.

Apr 3rd, 2022, 11:18	#9
Frenchguy New Member Last Online: Apr 3rd, 2022 11:37 Join Date: Jan 2020 Location: Chambéry	Hi will the noise increase when accelerating?

Apr 11th, 2022, 21:48	#10
Davezj Junior Member Last Online: Feb 16th, 2024 20:38 Join Date: Mar 2020 Location: Sale, South Manchester	Unforyunately if you have cracked off parts the head casting that holds the liters in place in my experience it is a new head required. but i dont think that is the source of you poping noise. the popping is probaly just a vacuum leak.

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