D5 (D5244T to 2005) Loss of power on hills/no kickdown

[johnfenwick10]

In November, I posted the following thread and no-one, in the Forum, was able to offer a suggestion. Unfortunately, after two further visits to the Volvo garage, the problem still exists. It's really frustating, having such a powerful car, that can't overtake on hills. Can anyone suggest any tips please? : I have a 2002, S60 D5 2.4 turbo diesel automatic. It's been a flying machine and no trouble until last week when I attempted to overtake by using the kickdown function. The car went into limp home mode. I took it to the Volvo garage, where it gets regular services, and they replaced the MAF which returned the car to driving normally, except the kickdown doesn't work at all. It seems to jam itself into 3rd gear and it won't go past 60MPH while in the kickdown mode, it's especially noticeable on hills, where overtaking becomes impossible. By easing off the accelerator the gear switches to 4th and normal power resumes. I took it back to the garage and they checked on the lower two engine mountings, fuel filter and the air hoses, but cannot find a problem. The computer delivers the message "Engine Service Required" but the Volvo garage's computer can't seem to diagnose the exact problem. Does anyone have any ideas????

[gadafi]

Hi,

Does the car enter into Emergency Mode when the "Engine Service Required" appears? It may be the turbo valve. I will aslo suggest you going to a Bosch Service garage. As you will know our cars have Bosch units, and their reading of the failures may give you a better idea of the trouble.

Cheers,

[johnfenwick10]

Thanks Gadafi. I'll go to a Bosch place and give it a try.

[gadafi]

Keep us informed please

[stuart_indalo]

Hi John,

Is all good now? I have stuttering engine with engine service required coming on.

I have changed the fuel filter, replaced the "soft pipe" going into the turbo, removed a ton of carbon gunk form the EGR and air inlet manifold and am crossing my fingers all will be well.

Stuart

[hitec s60]

Hi!i have that problem with 'engine service required' <volvo s60 d5 2003 >
ecm 6805 so i changed maf and turbo boost sensor,
that didnt help...but i found leaking intercooler so changed it aswell and still nothing..
turbo works only for 15-20 secods and goes off....
tonight i ordered brand new solenoid valve...and i hope its gonna work..
at the moment i can say that my volvo is the most expensive in north west

[v_matt_v]

I had similar symptoms as you have. I managed to solve my problem by replacing the turbo. There are couple of things you can do:

1. Clean EGR mixer
http://volvoforums.org.uk/showpost.p...6&postcount=56

2. Replace the fuel filter

3. Check turbo hoses and intercooler
Have a look here:
http://www.volvoforums.org.uk/showthread.php?t=69443
http://www.volvoforums.org.uk/showthread.php?t=93560

4. Then you have to check if there is no vacuum leak. Check the engine pads, hoses and vacuum pump:
http://www.volvoforums.org.uk/showthread.php?t=88190

5. Check the VNT valve (governor) - it might have to be replaced. This is the first thing you replace when suspecting faulty turbo. This valve controls the turbo and sometimes it fails.
http://www.volvoforums.org.uk/showthread.php?t=83830
http://www.volvoforums.org.uk/showthread.php?t=71445
6. Check the injectors. That's very unlikely but they also might casue ECM-6805 problems

7. The last thing is the turbo

Here is my thread http://www.volvoforums.org.uk/showthread.php?t=93130

[hitec s60]

hello!thanx for help.
so everything you told me to do i already did it...
everything apart from that solenoid valve <which i am waiting for> and replacing turbo...
there is no any air leaks..one leak i had it was in intercooler but already replaced..

thing which makes me worry is funny noise - when engine is cold and i press gas to the floor i can hear 'rattling' noise from under the bonnet...sounds like turbo but i am not sure..
car has done 145 kmiles and has every service stamp...

tomorrow i should get that governor...i hope that will help me...

Matt,
thank you for response

[hitec s60]

ps: very sorry for my english - i know it's not very good..but i do my best

[DanielHoward]

I have been experiencing the intermittent power loss. I wanted to ask something. A friend of mine told me that since 2000 all diesel cars in the UK have been fitted with an "anti-pollution" filter in the exhaust. This tends to go wrong and it results in the symptoms we are observing, loss of power, with no error codes.

My friend tells me that the part costs like 400 pounds but that some specialist places take it away in favour of a hollow tube, and that testing for whether this filter goes wrong only costs 30 pounds to help you decide if this is the source of your problems.

Is this true of our Volvo diesel cars?

If this is the case then I can see the connection with people who have posted that a change of the fuel filter made a world of difference. This anti-pollution filter is also a filter so there may be a connection. Apparently my friend who does not own a Volvo but a French diesel car has had the same symptoms as us and like you failed to diagnose the problem. If you find that this is the problem after you get it checked then please post to let us know if I am correct as it will help others. I am going to check mine.

One question I have is this. I went to a friend's garage and he had the cheap OD2 diagnostics gadget that you buy online. He put the year and model of my Volvo but he found no error codes although my car has the Engine Service prompt on. I wonder if (as with Jaguar cars) there are some codes specific to the Volvo S60 that would not be included in the cheap diagnostic tool that you can buy from eBay?