Fully cleaned ETM, reassembled and still having issues Topic is solved

[abscate]

Excellent. You found your issue and probably the only issue!

With air leaking into the intercooler after the MAF, the engine is getting air that the ECU does not know about. That generates a boatload of misfire codes.

[TheRev813]

I'm already working on getting it out so I can get it fully cleaned out. The upside down mounting bolts for the radiator are spinning freely, and 2 metal brackets fell out on each side of the radiator once I loosed up the 4 corners. And the bottom transmission cooling line appears to be stuck in there it is a real PITA for sure.

If it doesn't play nice, I very well may bolt it all back together and do my best to seal it while it's still on the car.

[scot850]

The end plates that are supposed to hold the intercooler in place are only held in place on the intercooler body by double sided tape. Who in Volvo thought this was good engineering practice should be shot for incompetence!

It is worth disassembling and repairing as I found out when the intercooler brackets fail it allows the intercooler to rub on the radiator and hole the casing. I had the aluminum core repaired by a radiator repair shop, used JB Weld steel glue and some large headed self gripping screws to hold the bracket mounts in place. Way stronger than original. It will also be easier to clean and try repair the intercooler while out. You could look on e-bay for a good used unit also.

The radiator bolts are bolted through a nut on either side of the radiator and are supposed to go into welded capture nuts. They can easily break and spin. Spray plenty of PB Blaster on the top side of the threads and let it soak over night. Then try to get something onto the captured nut to hold it to allow the bolt to unthread or at least the head to shear off. You can easily replace it with a regular nut and bolt.

Neil.

[TheRev813]

FIXED!!!

So I couldn't get the oil cooler/trans cooler lines disconnected and didn't want to force it, so I did it while everything was still in the car.

I cleaned the intercooler tank, scuffed it up and used quikstik plastic epoxy putty to seal the cracks. I then added a nice thick coat of jb weld over that.

While reassembling I noticed that the 2 mounting brackets for the radiatorsignage were both cracked off and missing, so I had to get creative.

I drilled holes into the header panel, as well as the top of the fan assembly, and zip tied it all together. I'm going to fabricate something up for a better long term solution, but as of now high idle problem that previously existed is gone after cleaning the ETM, and the bucking/stalling is gone after the intercooler was sealed up.

Thank you all for your help!!