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D5 Euro V 2015 XC60 - my Rough Idle problem solved

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Old Nov 28th, 2021, 12:45   #1
G5pot
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Default D5 Euro V 2015 XC60 - my Rough Idle problem solved

Hi

New to the forum. Been trawling the internet and forums and done the research for D5 rough idle and of course there's loads of rabbit holes. Rather than post to ask and dig another hole here's how I solved mine in the hope people might come across it and give them some ideas if experiencing the same symptoms. It's just one solution of many problems that I can see exist with the D5 and this last gen EuroV is not without! Spoiler alert...no surprises.

It started on a long 500mile motorway run all was perfect before- after 400 miles I reduced speed to 50mph and out of no where the engine spluttered at 2500rpm when asked to load up. Really bad vibration felt through the car and I thought it was going to stall. But it kept going and I replicated the problem on every try. Got home ok but on idle was violently rough. Started the next day to see and it was still there, smooth through the rest of the range just idle warm and cold was rough. No check engine light and basic readout on torque app showed everything fine?

D5 2015 euroV (HDF engine cover and oil fill at the top right) XC60 AWD auto

Summary of symptoms:
Rough Idle
Always on start and when cold
Intermittent when hot
No check engine
No difficulty starting
No smoke at all start idle or driving
No hesitation through the range
No smell
Good Fuel in the tank
Passed MOT Emissions with this rough idle


Initial thought was fuel as filter hadn't been changed in my ownership but was still inside the service interval (of which was main dealer and up-to-date). Also thought it was a coincidence that this was the first time I'd used Morrisons Diesel that this was happening and it was just after the fuel panic buy. I thought sh1te fuel and empty station tanks - probably a load of water and deposits gone through the fuel system thanks to forecourt tanks being low level and sediment being stirred up and run dry.

No water when drained and volvo fuel filter black but ok nothing unusual but a new filter didn't solve the problem. I spent a couple of weeks doing the Italian tune up trying to use up the Morrisons fuel and replacing with 1.70/l v power. Also most STP diesel and injector cleaners at a high ratio it was almost neat!
It seemed to get better after this and was now more intermittent. Always rough on cold start then sometimes yes and sometimes no at traffic lights and drive throughs and, sometimes more violent sometimes just a slight miss.


So I thought injector(s). However it wasnt hard to start and there was no smoke and no smell. That's where I did a load of internet trawling and most problems seem to be before Euro5. At 80k miles for mine - yes they might have done but I couldn't believe an injector would fail that soon. Didn't bother with a leak off test as buying the kit I may as well have just taken it to my local specialist to do it who'd plug it in. Screwdriver and ear and everything sounded normal, checked all wiring connectors and wiggling made no difference and all injectors passed a basic resistance test with multimeter. So possible but unlikely...

Vacuum test...yeah I enjoyed that. Lit a hamlet and had a glass of metaxa but couldn't see any leaks. Although it was noted some tubes had signs of rubbing and wear from their various clips and holders which I'll keep an eye on. Possible engine mounts but didn't see anything. I do have the popping in the oil cap but all that to me is subjective on how loud it is etc so Vaccum nothing obvious.

Then did the usual cleaned the MAF with IPA which was clean anyway, recleaned the Manifold pressure sensor which I'd done.before and was surprised how much gunk had reformed on it but no difference.

So that left me at EGR and the more I thought about it and the nature of randomness seeming fine one minute then not the next the more it pointed to that. I left this avenue till last, after a month or so exhausting other possibilities because when I brought the car 12months ago I did a full service and strip of throttle and egr to clean as I do with all my car's so I didn't think it could be that gummed up! In fact prob 4000miles since I made the egr sparkle?

So took off the motor first and made sure it moved which it did no problem both the motor and the actuator *small* bit of lithium dry grease to ensure it kept moving. Then pulled off the throttle which was clean but had a film of wet oil. Sorry to disappoint but no revelation when I saw the EGR valve looked ok bit gummed up, maybe more than what I would expect for 4k miles but went on to clean it anyway whilst in situ. The back of the valve perhaps had a bit more gunk on it but again what did raise an eyebrow was how wet and sticky the gunk was, and I mean like fresh sealing tar you could string it out which is unusual. Ive always known it to be like stick road tar that would come off in clumps. Anyway checked the valve moved ok and reassembled. And much to my dismay it didn't make one iota of difference, to which point I gave up and phoned specialist to book in and plug in and see what VIDA says.

But then...having been driving it for 2 weeks now the problem hasn't returned and it's back to being smooth idle and smoother through the range that I hadn't noticed before. I'm guessing there was a bit of relearning to do with the ECU after unplugging the EGR. Still abit rattley when cold but it has been close to zero. Appointment is in a couple of weeks to the garage and will keep it to just check EGR operation and make sure DPF is still regen-ing. Will post update if anything of note

So what I'm trying to say in a nutshell is...and this is just my experience on this engine. I think it was EGR related and I can't pinpoint it exactly as it wasn't anything obvious. Maybe a sticky motor and actuator or valve all caused by Morrisons fuel which I won't ever use again!? Maybe just unplugging it helped? maybe a combination of all the above. I'm good with engines but I'm too old now to be crawling under cars and too poor to buy every manufacturers computer interfaces to read the data.

I know it won't be an epiphany to some but i hope someone comes across this thread and helps them when they're doing their own research, just to match up some symptoms.

As an aside while I have my microphone here...I Like my XC60 great looking car and great Mway cruiser but it is basically a Ford now and I probably won't be getting another. Ever looked under a the hood of an Evoque a Mondeo and an XC60 and see the similarities? Ever looked at a TD5 and puma Defender Engine and the D5? A real shame as the build quality isn't there anymore having replaced 3 out of the 4 door locks and a leaky rear window on this XC60.

Last edited by G5pot; Nov 28th, 2021 at 14:06.
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Old Nov 28th, 2021, 14:18   #2
37 RUBY
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Thanks for sharing G5Spot.

Where in the East Midlands are you? I have Vida and happy to plug it in to obtain historical codes.

I've got the Euro 5 in my XC70 D5 and plug Vida in periodIcally finding it had a couple of EGR codes so I clean it twice a year and reset throttle body position - touch wood no issues.

As for fuel, I used VPower over 20k miles and still experienced a fair bit of build up in the EGR but last 30k has been Esso Supreme with very little residue.
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Old Nov 28th, 2021, 14:29   #3
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Originally Posted by 37 RUBY View Post
Thanks for sharing G5Spot.

Where in the East Midlands are you? I have Vida and happy to plug it in to obtain historical codes.

I've got the Euro 5 in my XC70 D5 and plug Vida in periodIcally finding it had a couple of EGR codes so I clean it twice a year and reset throttle body position - touch wood no issues.

As for fuel, I used VPower over 20k miles and still experienced a fair bit of build up in the EGR but last 30k has been Esso Supreme with very little residue.
Hi Ruby,

Near the airport so other end. Thank you for the offer however that's kind of you.

I usually use BP as its local and good price and never had an issue with it. I was forced to use Morrisons last month after the panic buy. I even noticed in my land cruiser it was harder to start on Morrisons and that I couldn't find cetane booster anywhere locally but that's just speculating and I dont want to detract the thread from the fact it was prob EGR.

I suspect it had an electronic wobble due to the sudden onset but it's good to know thanks for the info. And for the offer again.. appreciate it.
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Old Nov 28th, 2021, 14:37   #4
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Originally Posted by G5pot View Post
Hi Ruby,

Near the airport so other end. Thank you for the offer however that's kind of you.

I usually use BP as its local and good price and never had an issue with it. I was forced to use Morrisons last month after the panic buy. I even noticed in my land cruiser it was harder to start on Morrisons and that I couldn't find cetane booster anywhere locally but that's just speculating and I dont want to detract the thread from the fact it was prob EGR.

I suspect it had an electronic wobble due to the sudden onset but it's good to know thanks for the info. And for the offer again.. appreciate it.
I think you're on the right track with EGR. I have had numerous "EGR low flow value" codes registered. No running issues but then I've been keeping it clean.

're plugging in Vida, no worries - if you're ever floating past J29 M1 it's not far to my village.
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Old Nov 28th, 2021, 14:54   #5
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Just out of interest did the "EGR low flow" trigger a check engine light or was it a "soft" value hidden away and only visible when you plugged in?
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Old Nov 28th, 2021, 15:30   #6
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Just out of interest did the "EGR low flow" trigger a check engine light or was it a "soft" value hidden away and only visible when you plugged in?
No check lights, soft "Amber" warning only.... but for one warning, I did notice an unexpected passive regen that coincided with the code date and time.
Both regen & code were after a hard run with caravan down to Cornwall with ambient temp at around 20 deg and just prior to coming to a final halt.

It's a fickle system which needs keeping clean me thinks.

Last edited by 37 RUBY; Nov 28th, 2021 at 15:35.
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Old Nov 28th, 2021, 16:00   #7
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Originally Posted by 37 RUBY View Post
No check lights, soft "Amber" warning only.... but for one warning, I did notice an unexpected passive regen that coincided with the code date and time.
Both regen & code were after a hard run with caravan down to Cornwall with ambient temp at around 20 deg and just prior to coming to a final halt.

It's a fickle system which needs keeping clean me thinks.

Funny must be the sea air I was on a return trip to pick someone up from Cornwall when it happened - I didnt fuel down there.

Surprised it doesn't trigger light as a P0401 code?

Possible DPF issues to as the two systems are linked. I wont regurgitate the in and outs of EGR operation but if EGR not working correctly (stuck open closed or anywhere between) it will a) increase particulate/soot output and b) struggle to regen by increasing EGT so might be the reason for the regen?

Either way I agree, the electric operation is great when it works but a lot more sensitive and less reliable than Vacuum operated. Add to that the complexity and requirement of cooling the gases now, and as the internet says, you have an extra service item to be completed. As you say a couple of TB gaskets and regular cleaning should keep it at bay.

I have sealed the oil blowby/pcv thing on the the intake tube well now to so that will contribute to my woes as opposed to blowing oil all over the engine. And I really CBA to fit a catch can even though looking in the intake manifold pressure sensor hole I know its well gummed up in there to. To add to my above I use the correct Volvo Castrol oil and change every 12 months/6-8K. I dont lose much oil other than what I would consider normal at 1/2l or so between changes.
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Old Nov 28th, 2021, 16:27   #8
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Quote:
Originally Posted by G5pot View Post
Funny must be the sea air I was on a return trip to pick someone up from Cornwall when it happened - I didnt fuel down there.
I'll go with that

Quote:
Originally Posted by G5pot View Post
Surprised it doesn't trigger light as a P0401 code?
No it doesnt. It's an Amber warning only. No action needed but for me I use it to gauge when the EGR needs a service.

Quote:
Originally Posted by G5pot View Post
Possible DPF issues to as the two systems are linked. I wont regurgitate the in and outs of EGR operation but if EGR not working correctly (stuck open closed or anywhere between) it will a) increase particulate/soot output and b) struggle to regen by increasing EGT so might be the reason for the regen?
No, the DPF is healthy with a reasonable soot level but I don't use the car for short journeys. When I checked the EGR valve I could feel gunk stuck to the valve shaft and cleaning it properly seemed to resolve the issue.

Quote:
Originally Posted by G5pot View Post
Either way I agree, the electric operation is great when it works but a lot more sensitive and less reliable than Vacuum operated. Add to that the complexity and requirement of cooling the gases now, and as the internet says, you have an extra service item to be completed. As you say a couple of TB gaskets and regular cleaning should keep it at bay.
A reset of the throttle body via Vida restores the engines inherent smoothness.

Quote:
Originally Posted by G5pot View Post
I have sealed the oil blowby/pcv thing on the the intake tube well now to so that will contribute to my woes as opposed to blowing oil all over the engine.
managed to get dealer to replace that under warranty. I have a good dealer with a head tech who owns the same car as me.

Quote:
Originally Posted by G5pot View Post
And I really CBA to fit a catch can even though looking in the intake manifold pressure sensor hole I know its well gummed up in there to. To add to my above I use the correct Volvo Castrol oil and change every 12 months/6-8K. I dont lose much oil other than what I would consider normal at 1/2l or so between changes.
I think a catch can would upset the system.

As for oil, same as you except I change it twice in a year and at 86k miles no usage to report.
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Old Jan 13th, 2022, 20:06   #9
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ok so my initial excitement and posting was abit premature...

The rough idle did return but its frequency less and clearing better when the engine was warm.

After going to the garage VIDA logged a misfire fire on cylinder 3 and glow plug fault on this cylinder. I cant remember the exact numbers but injector #5 values were way out in comparison to the other 4 however right at the top end of spec. RPM differences were wild at +/- 200rpm at idle.

Garage replaced all 5 with a known good second hand set (obviously reseated and sealed) to rule out an injector issue which with the single glow plug change seems to have cured it. Initially there was abit of the rough idle coming back but since done 1000 miles and touch wood the issue hasn't returned, even on the coldest of mornings.

There is the slightest of misfires that can be heard on first start which is probably number 5 and even on the second set of injectors Vida was showing the top end of spec.

But for now I'm happy with the car and the way it drives and call the problem solved for now. If it occurs again I might investigate the glow plugs further but I didn't realise just how expensive they are for these engines not to mention the varying voltages.
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Old Jan 15th, 2022, 11:19   #10
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I remember reading a few tales of the injector wiring harness rubbing on a bracket on 5 cylinder engines and failing, I believe for injector no. 5. Since you still have some abnormal readings on injector 5, could be worth investigating if the problem returns?
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