Throttle Body on D5 possible fix
 

Hi guys, this week the engine service light came up on my car (07 D5 S60 163bhp) and it lost alot of power so i had a friend whom works for volvo check it with his diagnostic machines, turned out to be a Throttle body fault, i removed the throttle body and cleaned it out along with the egr valve and the L shaped pipe leading to the intake manifold as it was full of carbon deposits, unfortunately this didnt fix the problem, so i had another look today and noticed the butterfly wasnt completely open, i removed the front cover and after inspection found there to be a tooth broken from the end stop, after a bit of thinking i drilled a small hole in the side of gearhousing and tapped it 3.5mm and screwed a screw in gently until the throttle flap now closed at dead centre, put all back together the power was back instantly, i drove it to the shops earlier and a few other short journeys and the light has now gone out too! If anyone else has the same problem id be happy to explain in more detail hope that helps it saed me quite a bit of money and its great to be back to full power.

Thanks
Tommy