01 S60 T5 manual with boost problems

Post by **precopster** » 05 Nov 2013, 01:59

I had my first drive of a manual car in more than 10 years the other day and the best part of it was that it was a 2001 black T5 S60 with only about 75K miles and with afew subtle changes.

Only problem is that it loses boost at half throttle DRASTICALLY.

The owner has literally emptied his wallet to independant Volvo repairers who either can't find a problem or say there isn't one.

He posted a video of the problem here:

During this drive he says he didn't let go of the throttle and you can clearly see it go off boost.

Things replaced so far:

1) MAF (the indie repairer put in a 0280 218 045 which technically suits the Bosch ETA cars not the Magnetti ETM)

2) IPD TCV and all new silicon vacuum lines

3) New genuine boost pressure sensor

4) Spark plugs with Bosch coppers 0.7mm or .028" gap

5) New IPD HD ignition coils

6) ETM checks out and has a healthy sweep test

All the garages that have looked at the car don't have Vida and their scanners have never shown a TCV code however my Chinese Dice picked up a TCV code as soon as we connected. I cleared the code out and then cleaned the ECMs connector with contact cleaner.

The car hasn't been rescanned by me for afew days however I'm curious to see if it returns. The driving problem is real. He has had the car dynoed and it's about 10-15% down on power overall.

My initial thought is that the turbo has a bearing resonance at mid-range speeds which severely slows down its ability to spool.

If anyone could throw in some suggestions or something that they feel would severely drop the mid-range boost of this vehicle please feel free to comment.

Post by **DGM** » 05 Nov 2013, 06:15

I would verify ; the wastegate operation and adjustment. Also the TCV hoses routing. The intercooler hoses for leaks. Are they properly set and tighten from the turbo to the TB. This IPD video on the subject may help.

IPD TCV Installation Guide

http://www.ipdusa.com/products/8900/120 ... 0-v70-xc70

You may try to reset the adaptatives.

Post by **precopster** » 05 Nov 2013, 13:16

Thanks DGM for your timely response.

I haven't personally checked the hoses but the owner says he has gone over both the TCV routing and the turbo hoses to check for leaks over and over. He has pressurised the intercooler hoses and found no leaks. He hasn't had a smoke test done as yet.

He has the IPD instructions and has reset the adaptives multiple times. When we cleaned the ECM contacts we tried to reset the adaptives once again.

I don't know if he has properly adjusted the wastegate with the IPD tool. From that IPD video the symptoms look just like improper wastegate adjustment. I'll find that out later today

benyos · Post by **benyos** » 07 Nov 2013, 01:24

Hi everyone,

First of all i'd like to say thank for precopster whos trying to help me to find out the problem on my car and opened this topic.

The tcv lines are connected correctly with new silicone ones. Tried learn the tcv but cant hold the boost on half throttle. I checked the cbv no torn , holes on it can hold pressure and vacuum as well.
Yesterday i hooked up a manual boost controller( max 10psi). I had the same boost drop

even if i disconnect the vacuum line from the actuator the boost hardly wanna come and same drop. How can the ECM controlling boost if the tcv is not in route?

I really wanna fix this problem and enjoy my car.

benyos · Post by **benyos** » 07 Nov 2013, 01:31

I made an other video here is the link
5th gear 70km/h accelerating from the cruise controll. I was keep holding the + button down.

IMSITTINGINYOURCHAIR · Post by **IMSITTINGINYOURCHAIR** » 07 Nov 2013, 11:26

precopster wrote:My initial thought is that the turbo has a bearing resonance at mid-range speeds which severely slows down its ability to spool

Looks you have cleared all of the other possible issues. Is there a way to check that it is spooling properly at half throttle? this seems to be the last issue to look at.

benyos · Post by **benyos** » 07 Nov 2013, 12:26

IMSITTINGINYOURCHAIR wrote:
precopster wrote:My initial thought is that the turbo has a bearing resonance at mid-range speeds which severely slows down its ability to spool

Looks you have cleared all of the other possible issues. Is there a way to check that it is spooling properly at half throttle? this seems to be the last issue to look at.

Spool good till the drop. When it's drop and slowly start accelerating it doesn't want boosting. Feels like something holding back.

benyos · Post by **benyos** » 08 Nov 2013, 00:28

Does anybody knows how is the ECM cutting boost if the tcv is not in route? Ignition, fuel, etm?

benyos · Post by **benyos** » 08 Nov 2013, 23:36

This is what i tried today.
Installed a MBC (10 psi) disconnected the MAP sensor and connected to my old MAP sensor and left it in the engine bay. So the plugged one is reading 0 pressure but no CEL.

Now the boost come much faster and finally it HOLD BOOST.

Has power and much faster than it was before.
Definitely the MAP sensor giving wrong signal to the ECM and thats why was the cut. The new MAP sensor part number is 0261230029.
Could be a faulty MAP sensor or ECM problem? Getting closer!

IMSITTINGINYOURCHAIR · Post by **IMSITTINGINYOURCHAIR** » 09 Nov 2013, 00:14

makes sense. don't know why I didn't think of that. looks like it's reading high and cutting boost.

replace map sensor, re test. cross fingers.