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Mannyo - 2003 Volvo S60 D5 SE Manual


mannyo

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With the A6 gone, I now have another steed for commuting duties.

 

2003(03) Volvo S60 2.4 D5 SE Manual

 

Upgraded sound system (Dolby Pro Logic)

Full Leather sports seats

Dual Zone Climate

5 Speed manual

 

163K miles, one owner car with FSH although due another service about now.

 

One issue discovered after driving home from Bristol to Blandford, fuel leaking from two of the five diesel injectors at the fuel union.

 

Pics to follow.

Edited by mannyo
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Fuel, managed 50MPG driving back from Bristol to Blandford.

 

Road tax, just over £200. A lot less than both the old A6 and the current A8.

 

Dropped by a local volvo specialist today for a 5 min diagnosis, and its leaking from the injector seals and not what I thought. I have emailed the garage where I purchased it, still waiting for a reply. However the car I p/ex'd almost caught fire on their forecourt with electrical burning and smoke coming out of the engine bay.

 

So the car needs the two injectors removing, new seals and reassembly, assuming the injectors come out cleanly. He thinks they have been leaking a while, so removal could be difficult due to build up of debris. If they come out, he also recommends getting them tested which he can arrange locally for £30 each.

Edited by mannyo
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A nice option, hope the injector issue gets fixed smoothly for you :thumbup:

 

Garage have been in touch, they would like me to get a quote to fix the problem. I've now emailed the local specialist asking them for a quote.

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Look after belts and pully's and these engines run forever,

 

Spray some plus gas round injectors for a few days before you take it to garage to try and soften build up of gunk,

 

Its same lump i have in my xc90

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Well the car is with the specialist, they are replacing all the injector seals for all 5 cylinders.

 

However, bad start to injector removal. Two out of five came out no problem, one which we thought was ok is stuck, and the two we knew about are also stuck. Injectors left soaking in something to free them and hopefully extract them using a puller. I hope they come out ok, otherwise I could end up needing three injectors.

 

Garage I purchased from are at this point being sort of ok, in that they were hoping for an easy repair. Looks like the total bill could be in excess of £500 (worst case). I have volunteered to pickup some of the bill, and the specialist are speaking to the supplying garage.

 

In the meantime I have a 1997 1.8 Vauxhall Vectra as a courtesy car. 100K miles, a little rust here and there but advertising plastered all over it.

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Good news, the injectors are now all out and in one piece.

 

next job is clean up all the carbon build up and other crap from the cylinder head injector bores, then install new seals and refit.

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  • 3 weeks later...

Still waiting to get the Volvo back from the specialist.

 

They put it all back together, but it was apparent there was an issue with at least one injector. All five were sent away for testing etc., they are now all working ok and in transit back to the specialist.

 

They hoped to have the car back to me yesterday, but the injectors had not arrived back. The specialist have been very apologetic this week, especially because they have had the car for almost three weeks now.

 

I am hoping they have also done the oil and filter change I requested, will speak to them again on Monday.

 

I've done just over 100 miles in the Vectra, only using it to use up some of the petrol I had to put in when I got it...

Edited by mannyo
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I got the S60 back today, three weeks in the workshop.

 

There is a long story to the injector replacement, and the car is now fitted with 5 second hand injectors from another car as two of the originals were beyond being salvaged.

 

Basic story

 

Take car in

Injectors removed the following day, three seized in head needed pulling.

Easter

Mechanic cleans out excess carbon caused by the leaking seals

Refit injectors using new seals, but running like a bag of spanners after being difficult to start.

Send injectors for testing and recondition

Two injectors declared dead at refurbishers, even after rebuilding.

Garage install returned injectors and two second hand ones using another set of seals, car running like a bag of spanners but better than before.

Remove all the injectors again, install a full set of known good second hand injectors with another set of new seals.

 

So thats lots of injectors and seals used, but its back running again.

Edited by mannyo
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Couple more things ticked off today, and discovered something else.

 

Full 4 wheel alignment completed on hunter alignment machine, had 2 goes on the machine as the first one was aborted because of a seized track rod end. They freed that off once the wheels were off the car and he could get a better angle on the heavily rusted nuts. All finished now, and the car is well within tolerance.

 

As both front tyres were losing air slowly both tyres were removed from the wheels, beading cleaned and then reseated the tyres on the wheels before they were all rebalanced.

 

It was whilst doing the wheels that the broken front spring was spotted on the drivers side. It was not spotted before the wheel was removed, and you could not see the break with the wheel on so it passed its MOT with that spring fitted.

 

So need new springs for both front struts at some point, but will wait for now.

 

After the alignment the car drives so much better, both front and rear were miles out. Steering feels more positive and it seems much better in a straight line.

 

Got 600 miles out of the first tank of diesel (70 litre tank), the computer range is very optimistic as after filling up its saying "Range to Empty tank 1000 miles".

Edited by mannyo
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  • 1 month later...

S60 still running well.

 

Broken coil spring now replaced with second hand part, done more mileage in this car than I would have liked.

 

Tyres now holding air, no loss to report in 4 weeks.

 

Discovered that if you go full throttle that as the revs build up I seem to get more black smoke than I would like out the back, maybe a consequence of this car being Euro 3 and not having a DPF.

 

Taking it to France in a few weeks, that will be a big test....

Edited by mannyo
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Maybe look at alternative mapping, to help with the smoke issue? I know I'd take that as a preferred option, rather than being lumbered with a DPF!

 

Also a few tanks worth of diesel with Miller's additive will probably help things as well. Used to find with my PD-engined Skodas I've had, that they'd run more smoothly and with less smoke, when using Miller's in each tank.

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  • 3 weeks later...

Attempted to change the front discs and pads this evening, the ones currently on there are crusty around the edges and have had uneven pad contact for sometime.

 

So, new genuine discs and pads sourced direct from Volvo.

 

However not all went to plan, I got the calliper off and the old pads out but could not budge the carrier retaining bolts using what I have at home. So I've reassembled it all, and will let someone who has the right tools do the job.

 

in other news, next weekend with or without the pad change I am taking the Volvo to France for the annual holiday.

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  • 4 weeks later...

New discs and pads on the front are now fitted, my local Volvo specialist did the work in the end for an hours labour.

 

I had to trust the work was ok, as it was done the day before I left for a 2 week holiday in France.

 

This are the before change discs

 

post-47-0-20454500-1467825658_thumb.jpg

post-47-0-89848400-1467825659_thumb.jpg

 

These are the new ones, and they are wearing evenly.

 

post-47-0-83177900-1467825712_thumb.jpg

post-47-0-26341100-1467825713_thumb.jpg

 

I racked up 2500 miles in the Volvo over the 2 week holiday which highlighted no mechanical issues so the car is now going great.

Edited by mannyo
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