... And yes, it is surprising that that 1.9L engine holds 5.7 quarts of oil (according to the owner's manual.) Yep, 5.7 when you drain and replace the filter. PITA too because for my other 4cyl's I can just buy a 5q jug and have a little left over for top offs. For my Volvo I ended up buying 2 of t...

I would pull the upper plastic engine covers and look for pools of oil under the plug wires. Also remove the upper TB cover while you have the others off and check for oil there. I suspect that oil is collecting somewhere and when you go uphill it runs down the back of the engine and onto the exhaust.

Livens, Did you ever solve the PCV trap issue? I have a 2001 S40 1.9T with positive pressure (using the glove test) and yet the dealer is telling me that everything is fine. No, I've been too afraid and too poor :) The hoses are my fear, that one of them will break trying to get things apart. And t...

Not sure if it would be worth it at this point, but you should be able to find a mechanic that has a borescope. They can visually inspect the top of the piston and the valves for any obvious damage. Have you looked into the timing belt? Any chance that it slipped? Honestly, unless you get really luc...

When i changed my TB on a 2003 S40 the TB rode right on the inside edge of the cams, maybe just a hair off the edge. Tension was spot on... I was told this was normal as long as nothing was rubbing. 15k miles later and its still fine, and still rides in the same spot. Start the car up with the upper...

I thought of something else. I wonder if the exhaust cam gear (the VVT hub) was not positioned properly or torqued properly to the exhaust cam and it slipped. The cam gear (VVT) is fastened to the cam with a center bolt that is VERY tight. Something like 80 ft-lbs. I don't think you removed that ge...

I would start with the coils. Not likely maybe, but both of my coils in my S40 went out within a week of each other... right as it started getting hot last month. In both cases my coils had a fine crack running down the plastic post that connects to the plug. The hot temps were making those cracks s...

Any CEL's? A few things I would check first. Pull the plugs and make sure they look normal and are gapped properly, ~0.03" I believe. Also check your air filter. It could be your coils. When mine went bad they would run fine when the engine was cold, but once hot, especially sitting in traffic,...

I'm not sure about the 70 series, but I do have a 2003 S40. For one the 2000 is very early for the S40 and they did correct a few things in later years. A couple that I have heard of are the power steering pump lines leaking and a few weak points in the wiring harness causing shorts. For S40's in ge...

The issue is corrosion inside of the potentiometers that control the fan speed, air level and temp. I took my module apart a year ago and sprayed a product called Deoxit 5 on the pots and worked the back and forth as per the instructions on the can. This completely fixed the problem, fan speed was s...