Problem far worse after 'diagnosis' HELP!

[compaq1024]

Hi Everyone,

Long time lurker, first time poster. Background to the issue below:

I have a 2009 V50 D5. Its had been going really well up untill a few weeks ago when I noticed a very slight hesitation at around 2,800 rpm when the car was fully loaded.

It got progressively more obvious and then the dreaded EML came on so I took it to the Volvo specialist I had the cam belt done at - an hour away from home but 20mins from work near Birmingham.

They read the codes and got the below:

1890 - Swirl actuator control - Jammed
5660 - Oil level sensor - Signal too high
686D - Turbo control actuator - signal missing

They drained two LITRES!!! of oil as it looks like the DPF has been working over-time and dumping fuel into the oil system. Said bring it back next week and we'll see if the other two faults were linked to that.

Brought it back yesterday - the hesitation has not turned in to massive surging when accelerating above 2,800 rpm - as if someone has momentarily disconnected the turbo.

Read the codes and decided I need new swirl flaps (motors the lot) and to get my turbo reconditioned. With labour, parts inc oil change etc it will probably come to £1,400 IF they don't break an injector which I was told are £300 each if they are broken. Its booked in for next week at the moment.

This all seemed surprising they can diagnose the issue without lifting the bonnet but they are a specialist so assume they have seen the issue a lot and know what they are doing.

On the drive home all was not well, the car didn't come on boost at all. It would rev through in first without problems but it was as if there was no turbo. I struggled to get it past 60mph on the way home. Before going to the garage it would still pull really well and eventually power through the hesitation but this was totally different behaviour. I was being over taken my Micras and lorries.

I called them this morning and I was told nothing on the engine was changed or taken apart so it must just be a coincidence.

I have three questions

1. It is usual for someone to diagnose this issue without even going under the bonnet or having taken the car for a drive themselves?

2. Does that price seem reasonable?

3. It seems odd that the car was still coming on full boost when I took the car in and when I left it doesn't. Could this just be some bizarre coincidence or is it possible they did have a poke around and made the issue worse and don't want to admit it.

Any info/advice is really appreciated. I don't fancy taking heads off and messing around with swirl flaps, an oil change and spark plugs is about my limit to DIY mechanics.

Thanks in advance!

[andy_d]

which volvo specialists ?

i ask as i have used a couple in bham,

it might pay you to get a 2nd opinion before committing to use them

GRN motors in smethwick would be my recomendation

[SwissXC90]

From your description the quotes and diagnosis sound about right
Both jobs are quite labour intensive.

[Yobbo]

Originally Posted by compaq1024

Hi Everyone,
...
They read the codes and got the below:

1890 - Swirl actuator control - Jammed
5660 - Oil level sensor - Signal too high
686D - Turbo control actuator - signal missing
...
...

I have three questions

1. It is usual for someone to diagnose this issue without even going under the bonnet or having taken the car for a drive themselves?

2. Does that price seem reasonable?

3. It seems odd that the car was still coming on full boost when I took the car in and when I left it doesn't. Could this just be some bizarre coincidence or is it possible they did have a poke around and made the issue worse and don't want to admit it.

Any info/advice is really appreciated. I don't fancy taking heads off and messing around with swirl flaps, an oil change and spark plugs is about my limit to DIY mechanics.

Thanks in advance!

1. Yes - warning lights aplenty!
a) The Swirl Flap actuator arm falling off is a common Euro IV D5 fault, it simply wears loose on the ball joint - you can view this for yourself to see if it's dropped off, quick fix is a piece of nitrile glove over the ball joint and popping the arm back on. The so called specialist would be inspecting that if it was the case before assuming to replace parts at exorbitant cost.

b) Oil Level should be 5.5L at a target of 70% max in VIDA, it is remarkably sensitive. This won't cause a limp mode however...

c) The wiring harness that leads down to the turbo actuator has been known to fray from the connector - it won't cause a message to come up on the dash but if the signal is missing my money is on the wires... They can be fixed quite easily. To get access you'll need to get under the car and disconnect the connector to the actuator, the wiring loom is strapped on the air intake pipe to the turbo so you can cut the cable tie that secures it and then pull the whole lot up from the top of the engine bay for closer inspection. I think that the loom being strapped at a tight angle and without any slack causes the wires to fray with vibration, possibly along with the heat exposure too.

2. The price does not seem reasonable, not for what seems to be fairly trivial fixes IMO.

3. It's a possible coincidence, but going off your mechanical experience I am confident you can do this on your own. The head does not need to come off whatsoever.

Best of luck, I've only just seen this thread so hope you haven't been fleeced!

[Welton]

There's no way the turbo will need 'reconditioning' - modern diesel turbo units don't fail like that, it will be something simple instead.

Looks like the specialist was planning a little Holiday at that cost!

[compaq1024]

Thanks for the advice everyone! Turbo has already been whipped off and sent to be reconditioned so I'm quite far down the road already unfortunately.

I should have added its an ex-police car so everything breakable (suspension for example) has been completely replaced at least once...not the turbo however. Because of this it will have been driven hard from cold which could have caused parts (like the turbo bearings) to wear out prematurely.

I've not got the time or energy to diagnose it myself with a 4 month old at home. I'm just crossing my fingers and putting my faith in the indie specialist. Hopefully this means it'll be like new and good to go for another 90,000 trouble free miles without any other major issues.

You are both probably right and I could have made those fixes myself which would make it good for another XX,000 miles but I commute 65 miles a day and need a solid car that wont suddenly let me down. I'm hoping this will sort any issues once and for all.

Thats how I'm justifying this massive expense anyway.

[Yobbo]

Originally Posted by compaq1024

Thanks for the advice everyone! Turbo has already been whipped off and sent to be reconditioned so I'm quite far down the road already unfortunately.

I should have added its an ex-police car so everything breakable (suspension for example) has been completely replaced at least once...not the turbo however. Because of this it will have been driven hard from cold which could have caused parts (like the turbo bearings) to wear out prematurely.

I've not got the time or energy to diagnose it myself with a 4 month old at home. I'm just crossing my fingers and putting my faith in the indie specialist. Hopefully this means it'll be like new and good to go for another 90,000 trouble free miles without any other major issues.

You are both probably right and I could have made those fixes myself which would make it good for another XX,000 miles but I commute 65 miles a day and need a solid car that wont suddenly let me down. I'm hoping this will sort any issues once and for all.

Thats how I'm justifying this massive expense anyway.

I've had my pants down by a Volvo specialist in the past and to be honest I'd rather not spend money I didn't have to... I tried to justify the costs but after I got stung the second time by their misdiagnosis I decided to invest in tools and work on the car myself.
Trust me - it's the wiring or the acutator itself, if your turbo was knackered, i.e. oil seals had gone or the compressor wheel had become damaged you'd have smoke and noise, on a D5 its virtually unheard of.

[compaq1024]

I'm sure you are right. If I didn't have a newborn at home and a new house to do up I would have the time/energy to do it myself.

At least this way I know that those two parts are good for the lifetime of the vehicle now.

[Yobbo]

Originally Posted by compaq1024

I'm sure you are right. If I didn't have a newborn at home and a new house to do up I would have the time/energy to do it myself.

At least this way I know that those two parts are good for the lifetime of the vehicle now.

That's fair enough, mopping up vomit and changing nappies is stressful enough.

Feel free to drop me message if you need help, I have some pictures knocking about of the turbo wiring fixes somewhere.

[compaq1024]

Originally Posted by Yobbo

That's fair enough, mopping up vomit and changing nappies is stressful enough.

Feel free to drop me message if you need help, I have some pictures knocking about of the turbo wiring fixes somewhere.

Thanks Yobbo! I'll be sure to drop you a message if I need any more help, sounds like you are the person to know. Loving your V50 mods by the way! Mine is an SE spec car on the outside so it looks bog standard but with a D5 under the bonnet so its good at giving BMW 525 owners a surprise.