D5 (D5244T to 2005) ECM6805 Cured?

[GSMGuy]

Ok, further on from the rough running, which is now fine - See other thread..

Today I set about finding out why I appear to have no low down boost, and am getting "Engine Service Required" EVERY time I go over 2500rpm, stored code being the good old ECM6805...

So, armed with my shiny new Mityvac kit - I set about doing some testing....

First, I pulled off the vacuum takeoff from the vac pump, and popped on the mity... Vacuum is being produced, but tbh - not much, and it's not steady, although this may just "build up" in use...

Next, I connected the mity to the hose taken from the pump, and proceeded to apply a vacuum... Or at leat I tried, engine off or running, no vacuum could be produced,,,

Next, I checked that the front engine mount held a vacuum on it's own, which it did - Now the rear one is a pig to get to, so whilst studying the pipework, it appears that the vac from the pump tees off just below the EGR are, one feed going to the solenoid on the front of the airbox, the other to the turbocharger control solenoid located on the block, just below the common rail - So, the valve on the airbox ONLY controls the engine mounts.... Hmm...

Pulled up this valve, and detached both the vacuum in, and the mounts out pipes.. Tried a vacuum on both, the engine mounts both held, and could be heard to audibly "click" when vacuum was applied/released - more noticeable with the engine running... On the other pipe, no vacuum could be held...

Now I have said all along that I think it's a vacuum issue, so next I disconnected the output pipe (goes to the vane actuator on the turbo) from the turbo control solenoid, and applied gradual vacuum - I could actually heatr the actuator moving on the turbo - Time for some inprovisation - Applied 15" vacuum to this, and secured the mity under the bonnet, plugged the other pipe and went for a spin - BINGO takeoff was immediate and boost was plentiful.... So now, I just have to find the leak...

Mike

[GSMGuy]

BYW - There is a Volvo procedure for a quick check that the VNT vanes are working correctly...

Checking the variable nozzle turbo control

Preparation
Raise the car.
Remove:
-the splash guard under the engine
-the hose for the variable nozzle turbo regulator.
Connect vacuum pump 999 5843 to the regulator.
Create a negative pressure of 48 +/- 2 cm/Hg using the vacuum pump. The control arm on the variable nozzle turbo should reach its limit position at this pressure.
If not, the turbocharger (TC) must be replaced.


Mike

[GSMGuy]

Right, no time to talk now, gotta go get the kids - BUT I HAVE CURED IT! Just been for a 10 mile THRASH and not one single hiccup or error, the car is TRANSFORMED! It has NEVER run this well in the 100,000 miles I have done since owning it for the last 3 1/2 years!

ALL of the hesitation from idle has gone, stepping on the throttle is like lighting the blue touchpaper - God only knows how well it would go if I had kept my tuninng box - IT NEVER went this well whils that was fitted - EVER

I reallly cannot believe the transformation!

Mike

[GSMGuy]

Just gotten in from a 390 mile round trip - Car behaved PERFECTLY, not one eror, not one lumpy cycle - cannot believe I have finnaly cured the prob - Drove it HARD for a lot of the time and still averaged 29.1 mpg too...

Going to bed now, been awake since 0645 on Mon morning without a wink of sleep - YAWN!

Mike

[NCS XC90]

Mike,
I love reading your posts. You really have that attitude of working through a problem in logical steps. Even better you are willing to share them with us so we can all learn/ use them when needed. Very interested to find out what you have done / found.
Neil

[R-P]

Someone with as many problems if not more than I have.

But you actually solve yours!!!!!


Excellent work, as always.

ALL of the hesitation from idle has gone

Wow, is that actually possible? I kind of rested in the fact it was and would always be a hazard to drive due to this unbelievable hesitation.


And I know it's a lot to ask, but if you happen to have them, a few pictures would be greatly appreciated. I haven't got Vadis up and running and visualising your progress without the drawings is hard.

[volvosrock]

Hi mike.

i am a new member..read your post and wondered can you help me sort my car lol.....i would sooner spend my money on someone who clearly knows what is going on than my local volvo garage!

Just thought I would ask. my 02 s60 d5 se is really struggling!

If not, no worries, keep up the good posts. Anyone know any good independents volvo specialists in Nottingham lol.

Cheers
A

[v70-xc90man]

Originally Posted by GSMGuy

Just gotten in from a 390 mile round trip - Car behaved PERFECTLY, not one eror, not one lumpy cycle - cannot believe I have finnaly cured the prob - Drove it HARD for a lot of the time and still averaged 29.1 mpg too...

Going to bed now, been awake since 0645 on Mon morning without a wink of sleep - YAWN!

Mike

hi mines a 54 xc90 d5 manual 132k, i can take mine to within an inch of its life and upto 120mph thrashing every gear and not getting the dash message and limp,until i tow my caravan up a hill then it happens,just changed the top turbo pipe tonight as it was kinder soft-hope it sorts it as little bits like governor and this pipe alone is best part of £200- getting an annoying and costly fault, ic looks clean with no leaks or oil visible????????

[v70-xc90man]

Originally Posted by v70-xc90man

hi mines a 54 xc90 d5 manual 132k, i can take mine to within an inch of its life and upto 120mph thrashing every gear and not getting the dash message and limp,until i tow my caravan up a hill then it happens,just changed the top turbo pipe tonight as it was kinder soft-hope it sorts it as little bits like governor and this pipe alone is best part of £200- getting an annoying and costly fault, ic looks clean with no leaks or oil visible????????

Just to say got my turbo replaced with a brand new volvo one and fitted via a Volvo indy and now car is fine even towing which it was a nightmare before,done a couple of thousand with the new turbo now and no ecm6805 code or turbo/air noises-glad to have finally put this fault to bed even though i change intercooler,turbo pipe and govener until a new turbo fixed it for good,so just to say even though it drove ok when not towing unless going up a very steep hill,it wasn't until you towed with it to put the car under load that the turbo fault really revealed itself as no smoke etc was ever present just air type noises sounding as though they were escaping

[mgnaylor]

Hi R-P

Thanks for the update, when / if I do actually find the fault, do I need to get the error code reset, or will it just run, only ask because volvo charged me £50 for the pleasure of finding this out.

Cheers M