XC60 D3 Engine failure

[ntailby]

Hi,

looking for valuable expertise and guidance. Sorry for the long post but trying to be thorough on the situation. Here goes...!

I own an XC60 (Dec 2010), D3 engine, FWD, R-design. Been experiencing coolant issues and now engine failure.

- Coolant clearly leaking from the bottom RHS radiator, radiator changed.
- Coolant continued to leak, mainly on cold nights (c.300ml every few days), garage diagnosed O ring on the coolant pipe feeding off the radiator was not sealing. Pipe changed.

Coolant loss continued (c.300ml every few days, and not necessarily linked to mileage). No signs of milky oil, no signs of gases/oil in coolant or white smoke from the exhaust to suspect head gasket. Although did notice the engine started to start rough and ave MPG reduced from 37mpg to 34mpg.

- Garage suspected the EGR was at fault, EGR changed.
- Coolant loss continued. Major coolant loss happened on a journey which was clearly a blanking rubber plug on the top of radiator had perished and under heat/pressure was squirting coolant.
- Blanking plug changed, and also 2 new glow plugs to address the rough start.

The following days the rough start was still present, but drove ok, although mpg was still poor. On day 4 coolant loss happened (c.300ml) no external or internal signs. On day 6 engine showed signs of loss of power, cabin heater was giving no heat, and then coolant header tank emptied itself with white smoke coming out of the exhaust. Engine stalled and won't restart. Strangely the 'Low voltage' sign appeared on the dashboard and engine wouldn't turn over. Tow truck home.

Garage managed to start the engine, exhaust gases clearly mixing with coolant system (i.e. header tank is like an exhaust pipe) and oil is milky brown.

Is this common signs of head gasket failure or something more sinister? Welcome advice before more money is spent. Thanks

[reggit]

No expert on this engine, and only an interested amateur - so may be totally wrong.

Suspect you've had a small breach in the HG to a coolant passage which has overpressured the cooling system causing stress and failure of the components you describe. This could also lead to slightly rough running as 1 pot would be down on compression.

HG has eventually failed in a more major way allowing oil/water to mix.

I would have thought that the coolant would show some sign of contamination though in the early stages of the failure did you have a sniff test done at that point?

[SwissXC90]

Sounds and smells like a blown head gasket to me.

If so, cross fingers and hope no more damage - but you can only tell when the head is off.

So take of the head, inspect for damage, assess how to proceed at that stage.

If only a head gasket, then plane the head, fit a new gasket, change the oil and filter (of course as the oil is contaminated) and flush, clean the cooling system and fill with new coolant (flush and clean needed as it has oil in it).

Drive 1000 miles then flush and change the coolant again (still will have some oil in it, takes time to clean it out everywhere).
And to be double sure flush and change again in another 1000 miles.

Of course, whether you do all of the above depends largely on the condition of the vehicle, and it's current market value, and your desire to keep it.
You may decide that getting rid of the vehicle as-is is a better option for you.

Your choice.

[chrisfr]

As above. Bet my dinner money its a head gasket. Oil and water dont play nicely. They are both meant to stay in their respective places and not mix. Oil in the water system is as bad as water in the oil. The head will possibly need a skim because it may be slightly distorted but If the car did not overheat you may get away with it. For the cost of a skim which lessens the chance of a reoccurance i would say it was worth it unless it was found to be perfect. The likelyhood of that though is slim.

[ntailby]

hi - thanks for your responses. Progress update....Head off ... situation is as follows...

Gasket has clearly blown between cylinders 2 and 3, head looks ok (not tested), but the strangest part is the gap in the engine block between cylinders 2 and 3 seems to have a hole! A few observations… (trying to understand if this is by design, manufacturing error or something else)

-Initial suspicion was the hole was caused by corrosion although second look the hole appears to be uniform, relatively smooth edges and is slightly deeper than the channel that runs across the cylinders
-If the hole is by design why only have this between cylinders 2 and 3?
-The head gasket shows coolant has been passing between the other cylinders, but not between 2 and 3, the channel is blocked and not easily removed.

Any insight would be much appreciated, many thanks in advance.

[SwissXC90]

Originally Posted by ntailby

the strangest part is the gap in the engine block between cylinders 2 and 3 seems to have a hole! A few observations… (trying to understand if this is by design, manufacturing error or something else)

Google Volvo D3 engine block (or is it a D5)?
Look at the pictures
None of the pictures I saw had holes where your's has a hole.