V50 D2 Engine stutter/hesitation
 

Hello all, hope you are well.

Last June I had injector 1 replaced as it failed. Mobile mechanic guy came out and changed it, then had to take it to a specialist to be coded and adapted.

All was well.

Then the cold weather starting setting in the injector started chuffing when cold and stopped when the engine was warmed up.
I assumed the copper washer/seal must be bust so I took off the intake piping and had a look at the area. There was black crud in the area so cleaned it all off.

Had the day off yesterday so got the garage to take a look and as suspected the seal was bust. That was replaced.

Now, the car has developed a stutter/hesitation when putting your foot down at 1600rpm up until about 2k.
There is a little splutter in 4th gear, but 5th and 6th gear is quite violent.
There also seems to be an electrical whirring noise when the car is under load and you're going up through the rev range.

Any ideas?

Checked with Vida today and there are no fault codes stored.

The only thing I noted was that the battery voltage was at just over 13volts. 13.3 or 13.5v

This is a brand new battery so no idea what's happened to it?

Car is in the garage today for them to take a look at it, see what they find.

Hi Petey, I've had very similar problems with my V50 D2 as well so would be interested to know how you get on. My car had been running really rough for a few weeks and then last week a couple of times the engine just cut out completely (I had this problem about 6 months back too but it was never resolved and last time, no fault codes relating to injectors showed on VIDA). Luckily i have recently taken out a used car warranty so it was taken to a volvo dealer who found fault codes on injectors 1, 2 & 3 "max learning limit exceeded" and a fault with the Mass air flow sensor. They have updated the software for the injector "learning" and the car did seem to run a lot smoother and checking on the onboard diagnostic menu which my car has, there are no codes showing now. I'm going to try replacing the Mass Air Flow sensor to see if this helps. However I'm concerned about the problem coming back and being stung with a bill for 3 new injectors (Volvo have quoted approx £600 each!!)...

Out of interest how much did you pay for your injector replacement?

I'll keep you posted.

The garage couldn't find the problem. Changed the fuel filter and put a bottle of Forte in it. No changes.

I too have those "Offset Learning at Max Limit" fault codes for injectors 1, 2 & 3. But only 2 & 3 now as number 1 was replaced. It cost me more than it should have as I got a mobile mechanic to replace the injector, but he couldn't code it in, so I had to take it to a Volvo specialist who coded it and ran adaptations. A software download from Volvo is needed to code in the injector. I believe from what I've found looking through Vida, you can still run adaptations, but I don't feel confident enough to mess with that.

I'm thinking and hoping that maybe the injectors have lost their coding or adaptations. However, I double checked my last fault code read and noted the code at the bottom;

https://live.staticflickr.com/65535/...8ed20dd3_c.jpg

Which relates to this part

https://live.staticflickr.com/65535/...6cecfea9_c.jpg

And is a new fault. Maybe this has broke and is the source of the electrical whine I can hear, or maybe Injector 1 is knackered?

Taking it to a Volvo Specialist to have a look at next Tuesday, same one I used to code the injector. Hopefully they can get to the bottom of it.

"Now, the car has developed a stutter/hesitation when putting your foot down at 1600rpm up until about 2k."

^^
Petey, did you try getting some sensor cleaner on your MAF sensor? If you get over to another meet and there is another D2 there, maybe swap MAF to see if that helps the issue? (I have had that exact issue on many previous diesel cars)

What mileage you at? seems a bit weird if you injectors a knackered already?

I haven't had chance yet, but nothing relates to the MAF with regards to error codes or can they be dodgy without putting a fault code up?

I'm hoping it isn't the injector to be honest, as you say it's less than year old.

Yeh fair enough, im just going by the symptoms you described rather than just the fault codes as there can be issues with the sensors themselves.

Just seems really weird if your injectors are at fault, unless some debris has made its way from your fuel tank.

What is the usual life expectancy of these injectors? My car has only done 83k which seems quite low for them to fail or have issues...

I think it's hit and miss. The 1.6 diesel engines are known to suffer with them, both versions 8v and 16v. I think it's bad manufacturing on Siemens/VDO behalf.

Injector 1 on my car lasted just over 110k miles I think it was.

Looking forward to Tuesday to get the car checked out. The hesitation is quite dangerous at times if I'm in the wrong gear.

Are you able to log every sensor output simultaneously using the vida software? This might help diagnosing issues which are not necessarily related to an error code. I recently had some trouble which turned out to be my fuelfilter, yet no error codes showed up. Although I own a C30 the engine should be exactly the same.