D5 (2005 on) Volvo D5244T4 Limp-mode 3000+ rev Engine Service Required

[Vraces]

Hello everyone!

Let me tell you a little story about our Volvo V70 D5. A short time after we bought this wonderful vehicle the pipe that is connected underneath the engine to the turbocharger was detached due to the pressure and defective gasket. I thought not much of it and put the gasket back on and tightened the pipe a little harder to the turbo. Weeks later we went on a trip to our homeland. On our way back through Germany and their autobahn I was driving at 200km/h approximately. All of a sudden the car loses all its turbo capabilities and even worse, I can't drive faster than 20km/h. So we get off the highway slowly but surely and park somewhere near the highway. I attempt to make some kind of a gasket with a latex glove as I was desperate to get the car working again. This worked for a short time and then the pipe got detached again. So this time I disconnected the cable that goes to the EGR-valve thinking that this will allow me to drive the car without a turbo. Which it did. So I was driving a D5, 2.4D style all the way home. After getting a new head for the pipe and gasket I installed it and secured it tightly. Now I have another problem...

When I rev over 3000 r/min I get the message "Engine Service Required" and the car will not react to any further depressing of the gas pedal. Exactly no reaction. But if I fiddle with the gas pedal, releasing and depressing back and forth, the car resets and the power is restored to normal. But if I keep trying to go beyond 3000, 3500 and sometimes even 3700 if I'm lucky, then I get this problem again. I read the codes and I got Intake Manifold Swirl Flap and Mass Airflow Sensor. I changed the MAF but thought that the swirl flap function had nothing to do with this. I have changed, fuel filter, air filter, oil, oil filter, but still I haven't noticed anything that's changed. I even checked the EGR-valve to see if it's clogged or something, but I found nothing.

Things that I think about are:

* What if the latex glove or part of it went through the system and got stuck somewhere(although I probably removed all of it(unsure.))

* What if by disconnecting the EGR-valve I caused some other function in the car to take damage from that.

I miss my Volvo the way it used to be. So please if you have any knowledge, personal experience or friend's story then please do share. But please do not comment if you don't actually know what you're talking about. I'm already confused as it is and I don't have money to throw away.

I wait intensely for your answers, thank you.

[skyship007]

It's cheaper to try cleaning a duff MAF than replacing it. 50/50 chance a can of CRC or Halfrauds special will work.

A duff EGR will not do any real harm, BUT if you discoonect it that is an illegal act. Normally fiddling around with an engine in an attempt to clear a fault is not, but the EGR is part of the required emissions control system.
Alas it also partially invalidates the insurance as it is an undeclared Mod.

The latex glove might have caused the turbo fault.

[Vraces]

Originally Posted by skyship007

It's cheaper to try cleaning a duff MAF than replacing it. 50/50 chance a can of CRC or Halfrauds special will work.

A duff EGR will not do any real harm, BUT if you discoonect it that is an illegal act. Normally fiddling around with an engine in an attempt to clear a fault is not, but the EGR is part of the required emissions control system.
Alas it also partially invalidates the insurance as it is an undeclared Mod.

The latex glove might have caused the turbo fault.

Well I tried spraying it and as expected nothing happened, so I replaced it. At the time when I disconnected the EGR I didn't know it was illegal neither would I care if it was/is. I had an emergency and the last thing on my mind was mother nature. The turbo is working fine but when I rev hard it feels restricted. As if there is no air coming through or fuel. I have no idea how I'm supposed to look inside an inter-cooler to see if a piece of latex is in it. Sigh... That's life...

[skyship007]

Did you clean the intake manifold or use a spray cleaner when the EGR was checked ??
It needs doing every main cam service and would not cause the intermittent limp mode, BUT a badly clogged intake can upset the turbo.

[jamesey]

is the intake easy to take off and clean?