Engine: D5: Engine Low Power / Clacking Injectors

[Stellaman94]

Hello everyone, I'm new to the forums, I currently own an 07' Volvo 2.4D D5 SE Euro 4. In Auto

Lovely car, enjoying it more than my previous E46 320d, which unfortunately the gearbox blew up in it.

Currently the car is suffering poor power delivery, when I put my foot down, it is gutless. Now again when I start the car, within the first 5 minutes or so the car will have full power and its lovely but then it pretty much cuts all power and your better off riding a bicycle.

I've checked all hoses and vac lines which all seem to be fine, I've cleaned out the intake and the egr which had a fair bit of gunk in it, the stepper motor on the EGR recently burnt out which threw an error up on the dash, I recently replaced this and all was good, however it didn't solve the power issue. I had the dreaded swirl arm issue but managed to repair it with some metal wire, its still holding but I check it now and again, so far so good.

I have some issue with the injectors however, when the engine idles, instead of your typical diesel sound, it goes clack clack clack, I replaced 3 of the injectors which were out of tolerance, this was cylinder 1,3 and 5 all with new washers and clamps but still have the noise. The car starts on the key first time and never stalls. A part of me think the power issue is related to this. When I first got the car it made said noise but always had full power but just recently the cars been going down hill.

Edit: forgot to mention I recently changed the throttle body on the end of the EGR as the car use to rev up to 1500rpm and pull you along as if cruise was on, there was also a huge throttle delay and sometimes the pedal wouldn't respond at all.

Just a bit disappointed I can't enjoy 185HP worth of car.

[cheshired5]

Has it had any kind of code read recently, ideally with Vida?

[Stellaman94]

I know someone with a snap on and have had it read from that, it had an EGR fault which was the position sensor, accelerator pedal sensor fault (knackered throttle body) . Injector cylinder 1 and a cam sensor fault. All work relating to said codes has been corrected and the codes never reappeared, only the cam sensor fault appears for an unknown reason I can't remember the fault code specifically off the top of my head. But I'll try and get the codes re read on a snap on, I only have a basic reader at home and it doesn't display any faults, I do have a video of my car making that noise but have no idea on how to upload.

[cheshired5]

Just upload the video to YouTube and provide the link.

I would strongly recommend hooking up with Vida.
You'll get the Volvo code along with explanations of the possible causes and fixes plus it contains the workshop manual and lots of technical data to help with troubleshooting.
It pays for itself during your ownership then you sell it on and recoup most of your money when you're done.

[Stellaman94]

I've done various work my self with cars so I'm quite understanding, VIDAs like INPA and VAGCOM isn't it?

I will strip the EGR again as Ive only cleaned it while it was still attached to the car.

Here's the video of the injector noise, the camera doesn't do it justice, it is very audible.

I'll repost the codes if I get ahold of that snap-on machine again or a copy of that VIDA software.


https://youtu.be/Nvxn4H8RiWk

[Longhouse21]

VIDA is more like VAGCOM & ElsaWin combined. It has the diagnostics, repair instructions, parts catalogue and a few other bits in one package.

[Stellaman94]

There is one code I forgot mention which only seems to show up on the snap on.

4405 EGR intermittent

Now I did say before I only cleaned out the main valve and not the cooler, I have looked up on here about thorough cleaning but some have not had any luck in clearing the code.