Almost too many faults to list

[diplomat2.6]

We purchased a 1997 Volvo 850Tdi Cd Estate Auto 3 years ago. We have done 60k miles in it and it has been excellent, achieving an average 42-47 mpg since we've owned in. It now has 140K. I have changed oil religiously every 5000 miles and diesel filter every year. Brakes changed as needed. Just changed the ATF, CV boots and inner & outer track rod end.

However, there are now so many faults I am not sure which tackle first;

1) The ride height at the rear seems very low. It bangs and crashes over bumps and makes the children feel sick. It almost drags on the floor when we load the car to go camping. Should it have self leveling suspension at this age and spec? If so, if doesn't work?

2) After changing the oil, I went underneath to fit the liner whilst the car was warming up and there seemed to be quite a lot of knocking from underneath the sump cover. Anything to worry about or do all diesels do this?

3) Constant loud crunching from the driver's footwell on pressing accelerator or letting it go. When you are a passenger, it seems to be coming from the rear. The anti-roll bar bush looks tired but I am not sure this is it. I have already replaced the drop links but they didn't seem to be that bad. Noise continued. MOT passed in this condition. Ideas?

4) Top engine mount (rubber) perished and split

5) Brakes have plenty of pad left but they have gone very spongy and lacking in feel. Ideas?

6) Mileage is 140K. New cam belt at 160K?

7) Very tired and off centre front subframe bushes. Looks quite a nasty job to change them.

8) Rear tail gate wont hold up. Struts needed

9) AC compressor clutch slips constantly

10) AC system has a leak that nobody can trace. I've put cans of r134a in after having the system leak tested. Lasts about 2 weeks at full chill then drops off. No UV dye apparent anywhere. Evaporator?

11) Heater controls don't operate as they should. Several actuators don't seem to work and it doesn't do what you want it to. Fault code flashing but this is a recent thing and it doesn't seem any worse than it used to be when they weren't! How easy/sensibly priced are the actuators should they be needed?

12) The dashboard rattles constantly making me think it has been taken apart before. Has someone else taken the dash apart to fit a new evaporator and not put it together properly? Is this why heater flaps don't work (although several ac specialists have attempted to repair the system by replacing pressure switch)

That's it....

I really don't know where to start. I would be grateful of any advice that anyone may care to give. I wouldn't mind betting that there is more than the value of the car's worth of faults here. The trouble is that no car would suit our purposes nearly as well.

[Jaymz]

Most of your answers are just a search away, there are threads that cover most of the things you have asked.

As for the squeaky dash, if its anything like a V70 then welcome to your new travelling companions, Squeak 1, 2, 3, 4 friendly bunch they are, they do no harm, but can get on your tits

[capt jack]

Some thoughts on some of your worries:

Ride height and back end suspension problems could well be the top mounts - £20 apiece from Rufe for Volvo, less on ebay for non-genuine. Easy to check and fix. Self-levelling suspension is a more pricey fix. If the shockers have 'bellows' on the lower section you have Nivomats. If not you have standard shockers. Check out the top mounts first.

Engine top mount - if it's the same as petrol cars it's cheap and easy to fix - £20 or so.

Spongy brakes. Could just need a fluid change - it goes off and should be changed every 24 months anyway. A local garage did mine for £25 last time.

Engine knocking - high mileage diesels are noisy - what does your oil pressure light do?

Cambelt - every 80k I think for your car. Get a price from Volvo - you might be surprised. My (petrol) cambelt was changed last year by Volvo MD for £160 all in.

Can't answer all your queries, but hope that some of this helps a bit

Cheers

Jack

[tallrob]

Sounds like you need to visit a good mechanic with a case of beer. those could all be really time consuming fixes.

[Will_1223]

1) The ride height at the rear seems very low. It bangs and crashes over bumps and makes the children feel sick. It almost drags on the floor when we load the car to go camping. Should it have self leveling suspension at this age and spec? If so, if doesn't work?


2) After changing the oil, I went underneath to fit the liner whilst the car was warming up and there seemed to be quite a lot of knocking from underneath the sump cover. Anything to worry about or do all diesels do this?

3) Constant loud crunching from the driver's footwell on pressing accelerator or letting it go. When you are a passenger, it seems to be coming from the rear. The anti-roll bar bush looks tired but I am not sure this is it. I have already replaced the drop links but they didn't seem to be that bad. Noise continued. MOT passed in this condition. Ideas?

4) Top engine mount (rubber) perished and split

5) Brakes have plenty of pad left but they have gone very spongy and lacking in feel. Ideas?

6) Mileage is 140K. New cam belt at 160K?

7) Very tired and off centre front subframe bushes. Looks quite a nasty job to change them.

8) Rear tail gate wont hold up. Struts needed

9) AC compressor clutch slips constantly

10) AC system has a leak that nobody can trace. I've put cans of r134a in after having the system leak tested. Lasts about 2 weeks at full chill then drops off. No UV dye apparent anywhere. Evaporator?

11) Heater controls don't operate as they should. Several actuators don't seem to work and it doesn't do what you want it to. Fault code flashing but this is a recent thing and it doesn't seem any worse than it used to be when they weren't! How easy/sensibly priced are the actuators should they be needed?

12) The dashboard rattles constantly making me think it has been taken apart before. Has someone else taken the dash apart to fit a new evaporator and not put it together properly? Is this why heater flaps don't work (although several ac specialists have attempted to repair the system by replacing pressure switch)

Few answers to your questions:

1. Have you checked if your shocks are leaking, best way to test for broken/worn suspension is get two of you at the back of the car push down and up numerous times and then let go at the same time, a car with good suspension should only bounce 3-4 times then stop.

2. I work on volvo trucks and once we changed the oil and we go underneath they make the same knocky, clunky noise, its just something diesels do and you gotta remember the oil is travelling all round the engine, as said before though is your oil pressure light ok, if u wanted piece of mind get a pressure test.

3. You say its a loud crunching, could it be the accelerator pedal needs a bit of lubrication, also if you suspension is knackered then you gotta remember its putting all the weight of the car onto the anti roll bars so could well be all that side of things needs reconditioning.

4. Top engine mount is as stated, quite an easy job, you could proberly cut out the old one and then oil the new one and gently push it in and tap it here and there.

5. Brakes as stated before, needs a flush out, not a hard job but if you dont know what your doing get a garage to do it, good dot 4 fluid will make all the difference, also have you checked the level of fluid you have left, if its empty it would do simlar

6. Check when your last cambelt was done, they are 80k or every 6 years.

With regard to your air con in all honesty its probs best getting it ripped out with by the time you finished forking out for a compressor and then another regas it wont be worth it, this country dont get hot enough to really need it lol.

Also my dash board rattles as well, it may just be something with 850's/v70's a good smack normally shuts it up for a while

[diplomat2.6]

Well..thanks for all advice given. Here is the progress so far;

1) Clunk turned out to be a drop link that had failed (Delphi - only lasted 2 months)
2) New compressor purchased and fitted - (5 hours in all)
3) New evaporator and accumulator - (13 hours of hell in blistering heat)

[IMG]http://i205.photobucket.com/albums/bb278/virnuls/35057e8d.jpg[IMG]

There was a fault code registered on ACC unit which I haven't read yet. This was daft as the dash may have to come out again. I assumed that it was the low gas but the codes don't have this warning, it appears. I reckon it is going to be the actuators as the air doesn't want to go through face went. Now read guidelines for DIY pulse reader and purchased LED so nearly there!
4) No longer concerned with engine knock as that sounds normal.
5) Taking the dash out and tightening bolts seems to have cured the squeeks.

To do

Will change cam belt and shocks next year. They are self levelling type.
Bumper respray and top of wings where bonnet came unlatched and flipped backwards. Done bonnet already;
[IMG]http://i205.photobucket.com/albums/bb278/virnuls/DSCN1860.jpg[IMG]

Thermostat - doesn't seem to get hot very quickly

Interestingly, I have made a start and now I want to finish. I think it is my wife saying she'd like a BMW X5 that made me get moving on this! Imagine the trouble you could have with one of those!

[jetronic63]

Blimey that's a long list, makes me feel much better about my V70 ! - I sweated away a couple of stone at the weekend changing the stop light switch. Get fit and fix the car, what's not to like (please don't get an X5)