Euro 3 163 D5 Performance issues

[swil00]

Hi All,

I've been reading posts on the forum for a few weeks now relating to D5 163 performance / boost issues for a few weeks now.

These have given me great information on where to look trying to isolate my performance issues.

Around 6 weeks ago, I finally decided to get my car remapped by Shark Performance. Main reason for doing this was a noticeable drop in performance, which I put down to just being used to the car.

Car is a 2002 D5 with 97K. New clutch at around 50K due to a slave cylinder failure !

I thought that this gave me the ideal starting point for the remap.

Car gets a good run every day to work - 90 miles round trip.

So, the car was checked (albeit mainly software) and given the all clear and the map applied. Was told not to "nail it" straight away and allow the car to learn all its new values.

After a 15 mile steady drive home, I gave the accelerator a little prod and was very pleased by the immediate response. the remapped means that I've never had to floor it as such to make good progress.

However, in the first few days I noticed a noise when accelerating (Not sure exactly what sort of noise or where it was coming from due to the rain at the time.

After that, whilst accelerating up a hill in fourth, around 2000 rpm I noticed what I thought to be a dump valve noise. Being aware of the noise now, I tend to link it to a slightly different type of noise now, similar to a rally car of the early 2000's.

A work mate thinks it may be turbo stall ?

I've done some research and tested my engine mounts with a vac tester. Both the mounts and the hose holds vacuum ok.

The TCV on the front of the airbox functions fine, removing vacuum from the mounts at around 1500rpm.

The vacuum pump and pipe to the TCV provides a steady consistent vacuum.

Next was to remove the turbo governor on the block and clean it. It didn't seem too bad, but cleaned it with carb cleaner anyway. Seem's to have smoothed things out a little, but still get random performance and the boost issue around 2-2.5k rpm.

While the governor was off, I tested the vacuum to the VNT actuator. It held vacuum ok, but I cannot see if the actuator is actually doing anything until I get under the car.

Next thing to come across was the turbo inlet pipe. The lower one connecting to the turbo is very soft, so planning to replace this. The fact that the mounting bracket for the alloy inlet pipe being broken doesn't help the matter when the lower pipe is so soft.

I noticed on the post about replacing this pipe, someone mentioned that their one blew shortly after putting a BSR remap on... Hoping its something similar with mine.

While inspecting this, I noticed that PCV heater electrical connector was covered in oil and had sprayed onto the turbo pipe too. Does't look terribly fresh though.

I'm planning on getting a complete pipe (Top and bottom rubber hoses, alloy pipe and PCV heater nipple.

I have cleaned the PCV electrical connector up for now, but I may ask the local specialist his opinion on the PCV system at my next service in a few weeks.

[Max HEADVROOM]

i would of sorted the drop in power before remapping it

[swil00]

Fair point, but its only since the remap that I've really noticed it more.

Did 80k in it before remapping it, so plenty of time to get used to it.

[S60D5-185]

Originally Posted by Max HEADVROOM

i would of sorted the drop in power before remapping it

I agree and with 92k on a Euro 3 D5 it is barely run in and should have still been performing faultlessly with no power drop.

[davebb]

Hi take the fresh air pipe off and have a good look for splits, my D5 was 20 BHP
down on power because of this pipe being split and it did make a dump valve like sound, I could not see the slit from the top of engine bay,
shark have a very good name in Volvo tuning,
was the car done at there main HQ or one of the dealers,
as the 2002 D5 ECU Does NOT learn its new values, IT JUST USES THEM,
There is no adaption's with that ECU,
Dave

[cheshired5]

Originally Posted by swil00

was a noticeable drop in performance

The fix for this is to fix it not remap.
I have the same year D5 but with twice the mileage and it performs as new.
It hasn't always though.
A remap can really complicate fixing the root cause because the data produced isn't standard data so difficult to compare with how it should be.

Continue to cover the basics though with your fault finding and you'll hopefully come across the real issue.

[davebb]

Hi you could try putting the standard ecu file/Map back on and following Simon's videos run more Tests,
Dave

[Max HEADVROOM]

Originally Posted by davebb

Hi you could try putting the standard ecu file/Map back on and following Simon's videos run more Tests,
Dave

im sure the ecu has to be pulled out and bench mapped.

Al.

[Max HEADVROOM]

Originally Posted by davebb

Hi take the fresh air pipe off and have a good look for splits, my D5 was 20 BHP
down on power because of this pipe being split and it did make a dump valve like sound,
Dave

i replaced my split intake pipe just before the turbo and i still get the dump valve noise, specially when its just been fired up, then it gets quieter when warm..

Al.

[davebb]

Originally Posted by Max HEADVROOM

im sure the ecu has to be pulled out and bench mapped.

Al.

yes most of the time it has to be done on the bench, but shrk mte and rica do it using the obd2 port using the can-bus protocol,

the 1ST thing to do is use tourque app and see what the max boost and Mass air flow is on a good pull under load,
Dave