04 xc90 d5 cold starting problem

[Neilfinlay123]

This is my last post on this subject as I may sell my beloved xc90 if I cannot find a solution. Over the last year I have did the following:

1. Change glow plugs
2. Changed fuel filter (twice)
3. Leak back test carried out by Volvo dealership on injectors (all ok)
4. Leak back test carried out again by my mechanic, injectors removed, tested and sealed (all ok)
5.Changed coolant temperature sensor
6.Changed air flow meter and air box
7. Changed turbo solenoid valve
8. Cleaned turbo governor gauze.
9. Bought new battery.
10. Volvo tested fuel rail pressures, all ok
11. Changed diesel supplier

I am running out of things to change as you can see, my cold starting problem still remains. The engine starts perfectly after its heated for a few minutes, my starting problems occurs when the car sits over night and if it is below 3 degrees, the colder the worse it gets. I can start though with the slightest mistake of easy start in air box ( only as last resort). If I get the car started first thing in the morning it will be fine the rest of that day until the following morning. Does anyone have any idea what this could be?? I left it into a Volvo dealership in northern Ireland and they investigate d for a few days and still could not source the problem either. Really frustrating as the car is driving great but the early morning starting just doesn't happen, I have seen me hanging on the end of the key churning the starting for minutes on end with no joy. Please help if you have any ideas. Thanks guys

[skyship007]

What did the Volvo dealer say when they read the hidden fault codes ???

Some faults like a blocked EGR or fuel filter will not produce a fault code, but most other faults will and with a modern ECU controlled turbo diesel there is not much point changing anything, other than routine service items, until the fault codes are read, as it just becomes something of a guessing game.

[Neilfinlay123]

No fault codes identified. Volvo kept my jeep for over a week and carried out fuel rail pressure tests, checked glow plugs, leak back test on injectors, changed coolant temperature sensor, checked for air leaks, changed fuel filter, checked egr and cat. The technician mentioned that it could be the high pressure fuel pump not putting up enough pressure when starting. May hazve to change fuel pump as a last resort

[doolie]

Which garage did you use ?

[5cilinder]

"maybe" not enough fuelpressure? how is it possible that the volvo dealer cant read out fuelpressure when starting?
Fuel correction figures read out?
Or done compression test?

[skyship007]

If the OP had read the fault codes first, very few of the items listed would have needed changing.

If the engine is a high timer, it might be interesting to get a compression check done.

I would also try using a can of direct feed injection system cleaner like Liqui Moly Diesel Purge to fill up the fuel filter housing. Some of the additive will also finish up in the tank via the return line, but it also works as an in tank additive, so it's not wasted.