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Fully cleaned ETM, reassembled and still having issues Topic is solved

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
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1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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abscate
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abscate

Re: Fully cleaned ETM, reassembled and still having issues

Post by abscate » Sun Jan 01, 2017 8:32 pm

Excellent. You found your issue and probably the only issue!

With air leaking into the intercooler after the MAF, the engine is getting air that the ECU does not know about. That generates a boatload of misfire codes.
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TheRev813
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Re: Fully cleaned ETM, reassembled and still having issues

Post by TheRev813 » Sun Jan 01, 2017 8:42 pm

I'm already working on getting it out so I can get it fully cleaned out. The upside down mounting bolts for the radiator are spinning freely, and 2 metal brackets fell out on each side of the radiator once I loosed up the 4 corners. And the bottom transmission cooling line appears to be stuck in there it is a real PITA for sure.

If it doesn't play nice, I very well may bolt it all back together and do my best to seal it while it's still on the car.

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Re: Fully cleaned ETM, reassembled and still having issues

Post by scot850 » Sun Jan 01, 2017 10:43 pm

The end plates that are supposed to hold the intercooler in place are only held in place on the intercooler body by double sided tape. Who in Volvo thought this was good engineering practice should be shot for incompetence!

It is worth disassembling and repairing as I found out when the intercooler brackets fail it allows the intercooler to rub on the radiator and hole the casing. I had the aluminum core repaired by a radiator repair shop, used JB Weld steel glue and some large headed self gripping screws to hold the bracket mounts in place. Way stronger than original. It will also be easier to clean and try repair the intercooler while out. You could look on e-bay for a good used unit also.

The radiator bolts are bolted through a nut on either side of the radiator and are supposed to go into welded capture nuts. They can easily break and spin. Spray plenty of PB Blaster on the top side of the threads and let it soak over night. Then try to get something onto the captured nut to hold it to allow the bolt to unthread or at least the head to shear off. You can easily replace it with a regular nut and bolt.

Neil.
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Re: Fully cleaned ETM, reassembled and still having issues  Topic is solved

Post by TheRev813 » Tue Jan 03, 2017 5:50 pm

FIXED!!!

So I couldn't get the oil cooler/trans cooler lines disconnected and didn't want to force it, so I did it while everything was still in the car.

I cleaned the intercooler tank, scuffed it up and used quikstik plastic epoxy putty to seal the cracks. I then added a nice thick coat of jb weld over that.

While reassembling I noticed that the 2 mounting brackets for the radiatorsignage were both cracked off and missing, so I had to get creative.

I drilled holes into the header panel, as well as the top of the fan assembly, and zip tied it all together. I'm going to fabricate something up for a better long term solution, but as of now high idle problem that previously existed is gone after cleaning the ETM, and the bucking/stalling is gone after the intercooler was sealed up.

Thank you all for your help!!

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