V50 Engine D5 : Volvo D5 2008 (D5244T13 Engine) possible injector issues???

[Alex P]

My vehicle ran faultlessly since owning it and covering nearly 50k in the time I've owned it, I filled up the vehicle with diesel (55 litres) and due to short journeys to work I noticed a hard misfire around a few days later at 1800 rpm when accelerating in second gear.

The following day the issue was noticed again, and over each day the car slowly became un-drivable. At that time I thought that I might have filled up with contaminated fuel so I arranged the tank to be drained and refilled with fresh fuel along with a new fuel filter. The pipe work from the tank to the engine was not flushed through so if the fuel was contaminated it would be left in the pipes and would have been used by the engine until the clean fuel re entered the system again from the tank.

After this was completed the engine ran but was never perfect, occasionally the engine would rev cleanly only to return to problems with running, basically it would start fine as normal but wouldn't rev cleanly away from idle and you couldn't get the revs to 2000 rpm due to heavy hunting/ misfiring. Vida diagnostic by a garage showed nothing worth mentioning and It was recommended by them that the injectors and diesel system be tested by a competent diesel specialist who could remove and bench test the injectors and repair or replace any diesel parts as necessary.

I can't be totally sure the fuel would be the cause of these sudden issues and there could be another underlying fault which as manifested at the same time, although there doesn't seem to be any air leaks in any pipe work or any engine warning lights or stored codes/ logged issues in any diagnostic software.
I have since had a little help from a from a friend who had Volvo Vida diagnostic tool and he checked and recorded data from 2 tests in the Injector test section of that software. I've no idea what these figures mean but does it point to a injector issue looking at these figures or is there something else going on.

[Yobbo]

Consider the high pressure fuel pump, seems an odd problem.

[Alex P]

Yep the injectors and pump are on the query list. I suppose there's nothing else much mechanical left, there's no errors in Vida relating to anything sensor related. It's booked in to a diesel specialist who is going to leak test and remove the injectors for bench testing and possible overhaul.

[Alex P]

Right a bit of an update but still no joy.
The major hesitation is still there when accelerating around 1800rpm
and also slow running in traffic in second gear at 1800rpm. During this the engine will not rev through this point and the instant MPG drops to around 10-15 mpg??
The engine is the D5244T13 - Car V50 D5 R Design SE Sport

Had the injectors removed by a diesel specialistand bench tested, all came back fine and within spec so these were refitted by them. After this the garage said the car is fine but when I collected it the car wouldn't start, came back with crank angle position sensor fault so they changed this. Collected the car the following day but the hesitation was still evident on the way home even after the garage said all was fine on road test!!

Decided to take a look myself for obvious issues and found the EGR valve and TCM all gunked up so decided to take off and clean up. Whist here I changed the intercooler pipe to the EGR as this seemed soft and oily inside. Also changed the MAP sensor in the intercooler as this was oily as well.
Swirl arm is attached and motor seems to be fine.


There's no visible signs of leaks in the intercooler or associated pipework, the only vacuum pipe from the vacuum pump goes to the brake servo as the turbo seems to be electronic. Engine mounts are not vacuum pads as far as I can tell.
So here we are....still not resolved and really don't know where to look next, the car has ran faultlessly for 50k by me and then all of a sudden these issues arise.

The only thing I haven't changed is the MAF as I seem to be guessing now and parts will get expensive from here on. I've done as much as I'm prepared to do on the driveway and just wanted to share some figures out from VIDA if anyone with more experience can shed some light on these and compare against a good running car. Are the MAF Kg/h reasonable here or are they way off??
Any advice will be welcome before I throw in the towel with this one.

[Yobbo]

I keep bleating on about this all over the interweb, but it sounds like a boost problem - there are more cases coming to the fore at the moment where the wiring to the turbo electronic actuator has broken causing intermittent or dead boost.
It's believed that the angle of wires that exit the loom is a bit harsh, this along with the amount of heat generated in the area is likely why so many of these failures are occurring.

[Alex P]

Thanks for the advice, would it bring up fault codes relating to this though, I seem to be boosting OK and after 2000 rpm.... If I get it to clear that is! It pulls as normal with no noticeable drop in power.

Once I hit the hesitation (similar to running with heavy choke on in the old days) there's no way it will rev through it as it seems like the engine is bouncing off the rev limiter at 1800.
Changed the map sensor in the intercooler and now its flagging a P2227 code with a cheapo reader. Do I need to set the adaptation for this in vida or should it be just plug and play?
I'm really stumped with this now.

[cheshired5]

The most obvious observation I can make is that the data has always shown that fuel is not the issue, the injectors were functioning extremely well and any diesel specialist worth their name would have known that before charging for unnecessary testing.

Based on the data so far, my suspicion is that your MAF sensor is fine and your MAP sensor is fine too and always was.
My further suspicion is that the boost actuator is dead or dying.

With ignition on but engine off, get the ECM Parameters data for Mass Air Flow, Boost Pressure Actuator and Manifold Pressure.
Then the same data at idle and 1k, 2k, 3k, 4k revs.

[Alex P]

Thanks to all for advice, I'll get the results tonight and report back with the findings,
I take it the tests are obtained with just engine revs and not being driven?
As far as the garage is concerned I feel they really didn't have a clue and wanted to wash their hands of it without too much hassle for them..

Incidentally where is the boost solenoid found on this vehicle / engine configuration?

[cheshired5]

Originally Posted by Alex P

I take it the tests are obtained with just engine revs and not being driven?

Yes

Originally Posted by Alex P

Incidentally where is the boost solenoid found on this vehicle / engine configuration?

You have Vida so just use the comprehensive workshop manual to show location, replacement and signal testing information.

[Alex P]

Here are the figures of the requested parameters, Hopefully they can shed light on something. Incidentely Since I've replaced the MAP sensor in the intercooler I'm getting the ECM-1000 and ECM-1600 faults logged which never appeared before...??