2006 S40 T5 Losing coolant, cylinder misfire, more

[Volvo lover 724]

3 months ago I purchased a 2006 Volvo S40 T5, it is my first Volvo. I have had nothing but trouble since I purchased it. First it was losing coolant, I had the dealership replace the expansion tank cap, because they said it had a crack. Then it was still leaking coolant and so they replaced the expansion tank itself. Afterwards, still loosing coolant, I had it looked over by a Volvo master mechanic, he pressure tested the system and found no leaks, and kept pressure on it overnight and went down into the engine with a scope to see if perhaps the head gaskets were cracked. He found no leaks there either. The oil is not milky or bubbly. He replaced the thermostat, and still yet, I cannot keep coolant in the expansion tank. As soon as I put coolant in and drive somewhere, even a short distance, it is down below the min line on the tank when I started at the max line. I took it to another Volvo master technition and he pressure tested the system and also found no leaks.

Second the washer fluid just stopped spraying, I have a fulltank of fluid, and the motors are running, but nothing sprays out. Doesnt even try. I dont know if either situation is related but its driving me nuts!

Thirdly, the car is coding misfiring in cylinders 2 and 5. So as most normal humans would assume, it needs a tune up. I replaced the ignition coils with IPD USA R series coils, and Volvo OEM sparks plugs. Now the misfiring went from cylinders 2 and 5 to all 5 cylinders misfiring! I have contacted Ipd and am awaiting their responce. Can anyone help??

[fazool]

I can see your frustration. I had a 2005 S40 and had very good luck with it. Once you get these things worked out, hopefully you will have a better long-term experience.

First, your washers are totally unrelated to your coolant issue. You said the motor is running - can you hear the pump motor in addition to the wiper motor? I think that's probably the case. Its likely you have a loose hose or plugged hose or, worse case, a bad washer pump. They are cheap and easy to replace. Follow the hose back from the nozzle, disconnecting and testing until you find fluid coming out. Or to be quick and dirsty, disconnect the pump hoses and see if it squirts washer all over (to see if the pump is working).

As for your other bigger problem. I suspect strongly that you have a bad head gasket or warped head. Its is very plausible that coolant is getting into the cylinders and going out the exhaust pipe. The fluid in your cylinders could be causing the misfires.

I had the exact same problem in a differnt car years ago and it was exactly that - disappearing coolant, ignition/coil problems and misfiring. Turned out to be a warped head.

I'm not sure why a pressure test didn't catch this. Since you have absolutely confirmed fluid is disappearing it has to be going somewhere so there is obviously a leak somewhere. You can't have a leak *AND* have a successul pressure test. The only exception is if the pressure test didn't see the leak. Perhaps its so small and so gradual it wasn't detected. Or perhaps it only leaks when your engine is hot and everythign expands a little or perhaps the cylinder is sucking the fluid out of a tiny leak in the head gasket.

I would reccomend a pressure test when hot. And adding a strong flourescent dye to the coolant, running the car until you see coolant loss, then scoping the cylinders - I bet you will see dye in there.