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Crank but no start after swirl flap & injector replacement. 2007 Volvo s60 D5

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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Eiasen
Posts: 1
Joined: 7 December 2025
Year and Model: 2008 S60
Location: Norway

Crank but no start after swirl flap & injector replacement. 2007 Volvo s60 D5

Post by Eiasen »

To give the full story, for a couple of years the car has been going in to limp mode occasionally when giving full throttle or going up steep hills. The swirl flap actuator linkage was broken and a some google searching told me this could be the reason.

When doing the disassembly, i had to use an injector puller on injector number 5. I fitted all the new parts, new gasket for the inlet manifold cover, new swirl flaps, new linkage and new bolts brackets and copper washers for the injectors.
After i put everything together the car would crank but not start. Seemingly not even trying to fire on any cylinders, just cranking.
After more research i bought an injector leak off kit and found out injector number 5 was leaking pretty bad, probably something i did during disassembly.
So i bought a used one and fitted that, and when cranking this time it tried to fire just a little bit but nowhere near starting. So i was a little bit annoyed and tried using starting fluid. I have later found out this is not recommended at all by some people. Anyway, the car started after using starting fluid and was left on idle for about 20 minutes, after that i shut it off to finish putting back some other parts in the engine bay, like the top engine mounts and whatnot. When i try to start it again this time, it's the same again, crank but not trying to fire, and not with starting fluid either.

Can anyone point me in a direction? I would be most grateful.

Some additional information. I used a code reader unit to check the rail pressure, and with ignition on it was around 75 psi, and while cranking it topped at 6500 psi.
It ran pretty fine the first time i got it started, so i was thinking maybe rail pressure was the issue, that i didn't clean the washer seats good enough or something.

lrock
Posts: 122
Joined: 26 August 2022
Year and Model: 2001 v70 xc
Location: pennsylvania
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Post by lrock »

I'd start with double checking all my connectors and make sure i didn't miss any, i've forgot to plug my MAF back in and it wouldn't start. i'd inspect them for bent/broken pins and damaged wires, also checking all the ground connections where the coil packs are.

where did you spray the starting fluid in at?

never mind, i see it's a diesel now. i don't have any experience with them

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