2002 s40 1.9l turbo.... where do I start?......

Kdubya · Post by **Kdubya** » 31 Mar 2017, 10:05

Let me start by saying I'm a first time volvo owner and I bought it knowing it had a couple issues. It cold starts fine but once it starts warming up while idling in park my rpms fluctuate. Usually dropping pretty close to the point of stalling if not actually doing so. If I Rev the engine while in park there's usually an initial hesitation or stutter before kicking in. I also hear a loud whoosh sound when letting off gas pedal. While driving at low rpm and with a light load it doesn't do too bad except for coming to a quick stop will occasionally stall it out. During acceleration the engine stalls or hesitates very hard at around 2500-3500rpm. Its fuel consumption is also ridiculously high. It's throwing 12 ODB2 codes

what I know:
1. It was very poorly maintained
2. Seal in the exhaust cam gear is bad(inside of the timing cover has oil everywhere and there's some on top of the valve cover as well)
3.it's got 215k miles on it.
4. It's got positive crankcase pressure(did the latex gloves test)

what I've done so far:
1. Replaced cam sensor
2. Replaced crank sensor
3. New maf sensor
4. Replaced TPS
5. new plugs, ignition coils and wires
6. Replaced turbo boost solenoid
7. Replaced all the vacuum lines going into throttle body
8. Replaced IAC

Post by **alschnertz** » 31 Mar 2017, 15:30

Why did you change all those parts already?
Was it based on the 12 codes? What are/were the 12 codes?
Has the timing belt been replaced?
Are you sure the camshaft timing is correct?
Have you checked the other vacuum lines that are not connected to the throttle body?

Kdubya · Post by **Kdubya** » 01 Apr 2017, 00:37

Yeah I changed most of that based off the codes and then visual inspection and testing a few things. The timing belt has a sticker on the cover saying it was done just over 60k miles ago. How would i know if the timing was off? I thought if the timing was off in this type of engine there would be major damage ( bent valves holes in pistons major) As for checking vacuum I've checked as well as I could but don't really know the key spots to look. Today I also went ahead and dove into getting the pcv system removed and cleaned up. The bottom port was 98% clogged. a new oil trap and hoses along with the new intake manifold gasket should be here in the morning.

Post by **alschnertz** » 01 Apr 2017, 07:46

You can pull the timing cover and see if the index marks on the camshaft gears line up with the notches in the cover as well as the mark on the crankshaft gear. The one on the crankshaft gear is very difficult to see - especially if it's covered in an oily mess.
All three marks have to be lined up at the same time and they DO NOT indicate Top Dead Center.
You are correct that this is an interference engine, but being off one notch will not cause piston/valve damage. It will affect how well the engine runs though.

There are no "key" spots to check regarding the vacuum hose routing. Check 'em all. Hopefully a previous owner did not make the mistake of removing vacuum lines in an attempt to make it run better.
You should be able to read the Vacuum Hose Routing Diagram that is stickered under the hood.

Cleaning the PCV system is a good idea.

Check the PTC nipple. They have been known to clog. viewtopic.php?t=36184&start=10