Limp mode problem once hot - 06 C30 T5

[scot850]

I think in theory you could separate the manifold and turbo, but not sure if it can be done easily in the car. The engine bay in the P1 is tight!

Neil.

[scot850]

Latest update is hopefully the used replacement turbo is getting taken to the dealer today or tomorrow for checking and if all is good, get the parts on order and repair done. Fingers crossed!

Neil.

[scot850]

Got a text from the dealer today on the C30. Used turbo is fitted, but as I asked, they had scoped the intercooler, particularly the intake side. Sure enough a fair amount of aluminum 'glitter'. Oh dear. AS they are not confident they can clean the intercooler fully they are reluctant to try as they would be on the hook should a failure happen down the line due to the swarf. They also diagnosed the MAP sensor was recording erratically. It never seems to end. I broke the info and the $1500 quote for the parts and repair. I am ever more amazed and disappointed in the greed of Volvo on parts. A MAP sensor? Over $400 CDN?? It is a Bosch part and $90 delivered on Amazon! Amazon I consider overpriced.

So it looks like a Bosch/Amazon MAP sensor and a used intercooler. I will try to get to the junkyard over the weekend as there is a V50 in the yard which should have the same intercooler and possibly the MAP sensor still attached. At about $100 for a used intercooler still a little high but more affordable. We have also considered taking the intercooler to a radiator shop and seeing if they are willing to flush the intercooler. There is still the possibility of debris to not be cleaned out and coming back to bite down the line, so perhaps a used one and having that cleaned may be a much better option.

I had warned the owner this may happen so at least he was prepared!

Watch this space as they say!

Neil.

[scot850]

Well, been a long time. Got a text from the Volvo dealer. The TCV had gone bad again on the car. It had previously been replaced with a used part by a repair shop. So now the car has a good replacement intercooler and MAP to replaced the aluminum shaving contaminated originals as well. Apparently the car is now running well following the used turbo being fitted to replace the damaged original from a mechanic dropping a nut into the intake pipe.

The news is the car is currently running really well and no random pressure/vacuum codes being thrown. Hopefully that is finally it!

Neil.

[scot850]

Just went up to the dealer to collect the little red devil. He has asked me to help collect it as the wiring loom needs re-wrapped and a few other minor issues. His daughter (who the car is for) turns 16 today so I hope to have the car ready on the weekend for her to collect.

Drove the car back and no waring lights. Still not 100% happy with the idle. Still feels like a slight stumbling. However, the car now goes like I thought it should. Way quicker! Funny h ow a car runs better when the turbo impeller is not trashed!

Neil.

[scot850]

Owner picked the car up today. Drove it home and nearing his home near the south of Calgary a check light came on again!!

I'm beginning to wonder if it is how hard he is driving the car and especially now the turbo and other sensors have been replaced on the intake air and turbo system. Code is the infamous P0507 - Idle Control RPM higher than expected. It would suggest an air or vacuum leak again. This car has had every single item in the intake to cylinder replaced including the Intercooler, TB, MAF, TCV x 2 Vacuum seal in the intake case for the brake booster, and the MAP sensor, of, and the turbo that was damaged by a mechanic dropping a nut into the turbo intake replacing the head and gasket. The intake system has been smoke tested twice including the dealer. Nothing.

Makes me think there may be a torn hose or cracked pipe somewhere that only opens when the engine is run hard, or possible something random like the engine mounts are bad allowing the engine to pull on seals and pipes??

Were are the matches......................?

Neil.

[scot850]

Owner and his daughter (the car is for her) brought the car back.

Car is idling high around 1100 rpm.

Again had difficulty getting Vida to scan it. After some faffing, it eventually connected and looked for codes. Only code was for the head unit as before (bad CD unit).

Check light was on and he had scanned the P0507 idle air high code.

I used my Autel 802 and it pulled 3 codes. Similar to the ones I had before. ECM640C/950C/22 CC

640C -is turbo control. The car has just had a 2nd and this time new, Volvo TCV, and this one fitted by Volvo.

950C is the idle control signal error

21CC - Long term fuel trim idle, bank 1

Removed and refitted the MAF to Turbo cross-pipe again, and the wiring and spark plug cover to check for issues. Nothing seen.

Refitted everything, cleared the codes and started the car. It had a smooth 850 rpm idle and no faltering. Even when I drove it back from Volvo the idle was low around 750-800 and felt lumpy. Engine was smooth. Left it idling and rev'd a few times. All good. They drove about 30km home and all good. They then took the car out to go somewhere and after about 2 mins the engine check light came back on!!!

This is what happened yesterday. He left my house and drove to a gas station to fill the car. then 2 minutes later after starting, the check engine light came on?? What the heck??

Neil.

[Vova585]

I would try to do smoke test if able. Parts that were installed were not new(even new nowadays doesn't mean much), so possibly there is some issue...
This car is possessed by Ford.

[scot850]

Got the codes from his generic OBD2 tester. The codes have 'P' codes, but they look remarkably similar to the ones I pulled this morning. This car has been smoke tested twice already and nothing found. I could do this again, but I don't really have time in the near future as we are going on vacation in a week. I will go and speak to Volvo again tomorrow and see what they think.

Here we go again!

Neil.

[scot850]

Ok, I am hoping this is the final update on this issue!

I just got back from vacation. Just before leaving about 2.5 weeks ago the C30 returned to the dealer with more codes listed above and a fluctuating RPM issue. On my return I contacted the owner to get an update and the great news is the car is now running well, and hopefully continues to do so for a long time.

We were very lucky on this car, as you know we had amazing support from the Volvo dealer Royal Oak Volvo here in Calgary. There are those who rightly knock dealers and I have done this myself, however, I have continued to use them and they know me well and behave. This dealer whilst being owned by the other dealer in town has a new and enthusiastic service team. The service/parts manager is a former Volvo Master tech who I have known for about 15 years from the other dealership. He has brought together a good team and they work hard to maintain customers. I have seen the large shop go from near empty when first open to very busy as it is now in about 2-3 years.

Anyway, once they were able to get the car into the shop they had another bunch of diagnostics done on the car. They really took this challenge to heart and even involved Volvo technical to try to get to the bottom of this frustrating issue. And the problem? The recently installed Rock Auto throttle body the same shop fitted (owner supplied). Turned out it was a lemon.

They fitted a known good unit from another car at the shop and the issue went away. I had also supplied a used unit I had pulled from a crashed car (theory being the car was running when crashed). I have thoroughly cleaned it and it looked like new. They then fitted that and the car now has been running for a week or so quite happily and the young lady who is the proud owner is now loving her first car!

Her Dad is also really grateful to the dealer team. They waved the additional diagnostic charges which is amazing so he is over the moon. Does this mean all customers get this support? I would like to think so, but realistically this is more likely down to the relationship I have maintained over 20 years with the local dealers, them getting to know me and how I work with them and support Volvo as an enthusiast of more than 50 years.

I will continue to keep in touch with the owner and see if the car continues to behave itself!

Neil.