D19 - S40/V40 to 2004 - V40 1.9 D 2002 loss of power after rebuild...?

david27 · Jun 27th, 2012, 22:08

Hi girls and boys,

I'm after a little expertise if possible, my volvo V40 has developed a loss of power ever since a top end rebuild. The head gasket had gone, however, prior to this the engine ran fine. I have subsequently fixed the head gasket, rebuilt with all new gaskets, cambelt, tensioners etc etc.

The car started fine, and idled nicely so I was pleased all was well and put the rest of the car back together. Unfortunately the car wont pick up very well at all. There is a massive loss of power and it wont rev beyond 3.5k.

Things I've noticed:-
No smoke
No engine management light
I've re-timed the engine twice, and all still fine
No obvious leaks
No untoward sounds (inc using a screwdriver as a stethoscope)
The solenoid supplying vacuum to the turbo waste-gate is buzzing like mad and constantly appears to be actuating the turbo...?

The only thing I noticed that was wrong was the placement of the ?vacuum intensifier? thing mounted on the back of the inlet manifold, this was 180 degrees out, but the only thing this cured was the correct functioning of the vacuum shut-off solenoid.

Things I've tried:-
Buying a simple OBD2 code reader - no luck!
Buying a DICE unit - this worked (although in German!!) but failed to connect to the ECM, although was successful in connecting to all other systems (possibly reason why engine management light's not on??)
Disconnecting the battery for several days
unplugging various sensors to trigger management light (no luck - still no light)
Cleaning the inlet manifold - (the EGR is stuck fast and wont come out!!)

Any help would be very much appreciated, I'm running out of ideas...

Cheers,
David

gatos · Jun 27th, 2012, 23:30

Try posting in the S40 and V40 section too. Might have a bit more luck there. http://www.volvoforums.org.uk/forumdisplay.php?f=17

With regards to DICE, you should be able to connect and read the codes. Did you manually enter your VIN in DICE?

With regards to the EGR, try using some plumbers adjustable pipe wrench to rotate the inner part of the egr clockwise and anti-clockwise to break off all the crap and it should come off

Also see this guide: http://www.volvoforums.org.uk/showthread.php?t=127481

david27 · Jun 28th, 2012, 07:44

Hi, Yeah DICE worked to read all the systems apart from the ECM, which was boxed in red and stated i couldn't communicate with it. Also the language (ableit after running the patch) is in german, and I can find a way to change it... anyone else experienced this?

david27 · Jun 28th, 2012, 12:43

Also, yes i did have to type my VIN in, it couldn't decifer whether it was an S40 or V40 to begin with.

Jun 27th, 2012, 22:08	#1
david27 New Member Last Online: Aug 28th, 2012 13:10 Join Date: Jun 2012 Location: Stroud	V40 1.9 D 2002 loss of power after rebuild...? Hi girls and boys, I'm after a little expertise if possible, my volvo V40 has developed a loss of power ever since a top end rebuild. The head gasket had gone, however, prior to this the engine ran fine. I have subsequently fixed the head gasket, rebuilt with all new gaskets, cambelt, tensioners etc etc. The car started fine, and idled nicely so I was pleased all was well and put the rest of the car back together. Unfortunately the car wont pick up very well at all. There is a massive loss of power and it wont rev beyond 3.5k. Things I've noticed:- No smoke No engine management light I've re-timed the engine twice, and all still fine No obvious leaks No untoward sounds (inc using a screwdriver as a stethoscope) The solenoid supplying vacuum to the turbo waste-gate is buzzing like mad and constantly appears to be actuating the turbo...? The only thing I noticed that was wrong was the placement of the ?vacuum intensifier? thing mounted on the back of the inlet manifold, this was 180 degrees out, but the only thing this cured was the correct functioning of the vacuum shut-off solenoid. Things I've tried:- Buying a simple OBD2 code reader - no luck! Buying a DICE unit - this worked (although in German!!) but failed to connect to the ECM, although was successful in connecting to all other systems (possibly reason why engine management light's not on??) Disconnecting the battery for several days unplugging various sensors to trigger management light (no luck - still no light) Cleaning the inlet manifold - (the EGR is stuck fast and wont come out!!) Any help would be very much appreciated, I'm running out of ideas... Cheers, David

Jun 27th, 2012, 23:30	#2
gatos Premier Member Last Online: Nov 15th, 2022 21:34 Join Date: Apr 2010 Location: London / Essex	Try posting in the S40 and V40 section too. Might have a bit more luck there. http://www.volvoforums.org.uk/forumdisplay.php?f=17 With regards to DICE, you should be able to connect and read the codes. Did you manually enter your VIN in DICE? With regards to the EGR, try using some plumbers adjustable pipe wrench to rotate the inner part of the egr clockwise and anti-clockwise to break off all the crap and it should come off Also see this guide: http://www.volvoforums.org.uk/showthread.php?t=127481 __________________ Current car: 2002 S40 1.9D, 1992 240SE Nullius in Verba

Jun 28th, 2012, 07:44	#3
david27 New Member Last Online: Aug 28th, 2012 13:10 Join Date: Jun 2012 Location: Stroud	Hi, Yeah DICE worked to read all the systems apart from the ECM, which was boxed in red and stated i couldn't communicate with it. Also the language (ableit after running the patch) is in german, and I can find a way to change it... anyone else experienced this?

Jun 28th, 2012, 12:43	#4
david27 New Member Last Online: Aug 28th, 2012 13:10 Join Date: Jun 2012 Location: Stroud	Also, yes i did have to type my VIN in, it couldn't decifer whether it was an S40 or V40 to begin with.

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)