Help troubleshooting S60 Smoking Exhaust

S60 Blues · Post by **S60 Blues** » 14 Apr 2009, 19:06

So I posted the other day with only a single reply. I tell you I am new to the site and really need help. S60 started smoking from the exhaust & suspected either a head gasket or turbo. I believe I have narrowed down to the turbo but would like confirmation.

What I have checked so far:
Checked the oil it was low and dirty, my fault!
No visible water when I drained a 1/2 pint from the oil pan.
No foam or white sludge on the oil filler
Pulled the plugs, all five were nice chocolate brown
The tops of the pistons all looked fairly clean
Not confident with my compression test, readings changed every time with every cylinder. My tester is 20 years old.

Sorry I don't know the correct name of the part, its a black air tube crossing over the top of the motor. Starts along side the radiator and terminates in the turbo. Anyway its sprayed with oil on the turbo side. Hence, I believe my turbo is fried!
Thanks, I will be back later to reply.

Post by **matthew1** » 14 Apr 2009, 19:59

Do you hear the turbo spinning up when you step on the gas?

I'm guessing you don't, and that you already know what I suspect: the turbo's gone.

S60 Blues · Post by **S60 Blues** » 14 Apr 2009, 20:34

Is the oil I spotted confirmation of a bad turbo?

Its really not making any peculiar sounds. I do suspect the turbo lost its seal/bearing due to the dirty low oil. My days of practicing adequate neglect finally caught up with me!

So I don't have a repair manuel and it looks like they are hard to come by for the S60. I would appreciate any suggestions on how to tackle this repair.

Any tips on the removal and installation?
What else should I be repairing/replacing?
What do I do for a replacement, attempt to repair myself, I saw a post on rebuilding,
References on reliable rebuilders of turbos?
Any chance of harming any related systems during the repair?
Finally are there any other posts to refer too.

Thanks to all!!!

Post by **MadeInJapan** » 14 Apr 2009, 21:53

There is an oil return line at the base of the turbo that runs into the side of the engine block (when it goes, you can get oil spray)...get under the car (or have someone do this), clean everything off and see if this is it. It's not uncommon. If this is it, the parts to replace the 0-ring and seal (one on each end) are not expensive at all but the repair is a bit tedious and takes some contorting. That said, it's less than an hour of labor. Parts are available at several vendors: http://www.ipdusa.com http://www.fcpgroton.com or http://www.eeuroparts.com (my list of favorites). I would not count out the turbo yet as they tend to be pretty stout in our cars. More than the turbo I would suspect a clogged PCV system which are a series of small hoses and an oil separator that resides under your intake manifold (this would cause black smoke or blow-by). The PCV is about a 3.5 to 4 hour job to clean/replace (parts are not more than $140). If it's not the PCV and ends up being the turbo, I would check on both eBay as well as over on http://www.volvospeed.com in the for sale section for someone who has one from a car they are parting out. If not there then http://www.erievovo.com (call them as they are bad w/ email) will have one for you at a substantial discount over the dealer....but of course it will be a known good unit.
Good luck and let us know how things go.

Post by **matthew1** » 15 Apr 2009, 12:11

I'm not trying to be a negative downer - I hope it's not your turbo, and as MIJ said these turbos are robust. But very low oil will kill a turbo dead. That's what led me to suggest a bad turbo.

To determine if your turbo is shot, listen for the whine when it spins up. Or you can tell "by the seat of your pants" if there is less power. Either of those will tell you. Also, if your S60 has a boost gauge, that will tell you by simply not showing boost.

If you need to rebuild your turbo, MIJ has a post with his notes + with a link to a very detailed rebuild tutorial for a 15G - may or may not be the model in your Volvo.

S60 Blues · Post by **S60 Blues** » 15 Apr 2009, 15:41

Thanks to both Mathew1 & MadeInJapan for your help.
FYI, Once I spotted the smoking exhaust I have not driven it to prevent any further damage so I can't tell if it lost power.

Just to clarify the oil I found was on the inside of the air intake and inside the turbo intake. (I also have oil behind the engine and will check the oil lines to the turbo for bad o rings and gaskeets. I suspect that may of caused my loss of oil leading to a bad turbo.)

Due to the internal oil, I really have the blinders on and beleive its a turbo. Could a clogged PCV system, or anything other than a bad turbo, be the reason for oil on the intake side of the turbo? I"ll do any check you reccomend prior to pulling it.

Finally, could anyone help with the sequence of removing the turbo. I did ordered a repair DVD but it won't arrive untill next week and would like to attack this tomorrow. I am really going into this blind.

Post by **MadeInJapan** » 15 Apr 2009, 19:27

You'll always have a little oil in your turbo hoses and in your turbo...even a drip from the underside of the turbo is normal. If it's excessive it certainly could be that your PCV is clogged and not letting the oil in gas state (exhaust) recirculate in through your intake...and cause oil to be burned and thus your black smoke. What bothers me are the sudden on-set of symptoms so it certainly could be a bad turbo (like Matthew mentioned), so listen for the spin-up sound and for the feel when boost comes on. That said, here are the removal instructions for your car:

02 S60 Turbo Removal.pdf: (180.24 KiB) Downloaded 788 times

S60 Blues · Post by **S60 Blues** » 15 Apr 2009, 21:13

MIJ,
A Little Oil? The inside of the intake looked like oil was slinging around the throat and the impeller. Hard to estimate the amount, maybe a tablespoon or less. First time I have ever inspected the turbo so I have no idea whats normal.

So before I pull the turbo:
I'll fire it up, listen for the turbo then drive to check for boost. I'll also attempt to look the PCV hoses over to see if thay are gunked up.

Thanks again for the help. Hopefully I am not focusing on the wrong part!

S60 Blues · Post by **S60 Blues** » 16 Apr 2009, 19:23

So I had to work today and couldn’t get to the Volvo. It did give me a little extra time to do some additional research and develop a few more questions. My sudden onset of smoking exhaust, my low/ dirty oil along with the oil I found on the air intake side had me at least relieved that I knew what the problem was. Then MIJ stated that a little oil on the intake side is normal. Yikes- Am I focusing on the wrong thing???

So as I stated earlier I will look listen and feel for turbo operation. I assumed that the turbo is working but pissing oil past is seals or rings. Is there and definitive sighting of oil in any location that would confirm it’s a turbo problem? Like on the exhaust side of the turbo.

In checking the PCV system its such a big job that I am looking for any indicators that scream it’s the problem, say oil or gunk in any visible hoses. Easy access to parts is prohibiting me from tackling the PCV system rather than the time commitment. In my research generally a faulty PCV systems resulted in a lack of performance and puffs of black smoke. My car is pumping out a cloud of grey white smoke that increases with RPM.

I found the turbo rebuild is in the $600-$700 range. After viewing the rebuild tutorial Mathew provided I am considering taking on the rebuild myself. Providing I can obtain the parts is it a realistic DIY job?

By the way do you know the model of the turbo in my vehicle. 2001 S60 2.4T,I believe. I would also like the model # of the T5 if possible.

I really do appreciate all your help!!!!!

Post by **MadeInJapan** » 16 Apr 2009, 20:34

At idle, pull the oil dipstick...if smoke streams out, there's a good bet that it's your PCV. Turbo? I'm not sure what you have in your S60 but a little searching and you'll figure that one out- not as crucial. Everything on your car is mated with each other....the turbo rebuild isn't bad...I can even send you a file on how to do it if you want (Private message me with your email address) but you do have a few precautions to not fubar it.