S40 (New) Engine Turbo : Anyone had this?

[julianps]

S40 1.6D DRIVe 2010MY

Returning from Sheffield to the wilds of Wales last evening.

Picked up fuel on the way and sometime after had the ever-so-slightest inkling of a "misfire". Got to the pay station at T8 on the M6 Toll and could smell a lot of diesel. "Hope that's not me!".

Went on to the A460 and started to smell diesel getting past the stink-filter on the climate system. Pulled over just short of the M54.

Removing the top cover revealed, the foam padding on the underside saturated with diesel around the near-side in line with the socket that holds the cover to the ball-fixing. Fuel was beginning to run out of it down the near side of the block (around the fuel filter; that sort of area. No obviouse source, just evidence of flow.

Started the engine and no obvious problems. Had my wife run up to 1,2-1,400rpm and, under torch light, could see a fine mist of fuel firing out of the smallest of pin holes in the steel hose connected to the near-side injector (#4?).

My guess is that when the car was running close-on 100% of the fuel in the system was being burnt but on the over-run, tick-over, etc it was leaking and being collected in the foam padding. Until it could hold no more and started to flow out.

Questions;

1. Anyone else had this?
2. Is replacing a hose an easy fix or do I then need to bleed the fuel system (or perform rain dance, or other procedures)?
3. Are these metal hoses generally poor quality and if procedures required (bleeding/incantations to the God-of-hellfire) should I just replace all four hoses while I'm at it?
4. The car was trailered home (Selekt) so stands unused; is there anything else I should be looking for in the way of consequential damage or otherwise considering in the home of minimising unintended consequences?

Thanks in advance for your thoughts and observations on this.

NB; tip-o-the-hat to Selekt/Mondial who got to us in 25 minutes, assessed quickly, got immediate approval for assistance and had us back within 25 minutes of the time we'd have achieved if we'd been able to get home under our win steam. Let's hope our dealer is as good at keeping things painless!

[oyvolvo]

Originally Posted by julianps

S40 1.6D DRIVe 2010MY

Returning from Sheffield to the wilds of Wales last evening.

Picked up fuel on the way and sometime after had the ever-so-slightest inkling of a "misfire". Got to the pay station at T8 on the M6 Toll and could smell a lot of diesel. "Hope that's not me!".

Went on to the A460 and started to smell diesel getting past the stink-filter on the climate system. Pulled over just short of the M54.

Removing the top cover revealed, the foam padding on the underside saturated with diesel around the near-side in line with the socket that holds the cover to the ball-fixing. Fuel was beginning to run out of it down the near side of the block (around the fuel filter; that sort of area. No obviouse source, just evidence of flow.

Started the engine and no obvious problems. Had my wife run up to 1,2-1,400rpm and, under torch light, could see a fine mist of fuel firing out of the smallest of pin holes in the steel hose connected to the near-side injector (#4?).

My guess is that when the car was running close-on 100% of the fuel in the system was being burnt but on the over-run, tick-over, etc it was leaking and being collected in the foam padding. Until it could hold no more and started to flow out.

Questions;

1. Anyone else had this?
2. Is replacing a hose an easy fix or do I then need to bleed the fuel system (or perform rain dance, or other procedures)?
3. Are these metal hoses generally poor quality and if procedures required (bleeding/incantations to the God-of-hellfire) should I just replace all four hoses while I'm at it?
4. The car was trailered home (Selekt) so stands unused; is there anything else I should be looking for in the way of consequential damage or otherwise considering in the home of minimising unintended consequences?

Thanks in advance for your thoughts and observations on this.

NB; tip-o-the-hat to Selekt/Mondial who got to us in 25 minutes, assessed quickly, got immediate approval for assistance and had us back within 25 minutes of the time we'd have achieved if we'd been able to get home under our win steam. Let's hope our dealer is as good at keeping things painless!

looks like injector pipes will need replacing (they operate at extremely high pressures and there is no way to mend them) independant workshop may be cheaper if you can find a good one. then its just getting rid of diesel smell !

[julianps]

The car went to my local dealer (it's still in warranty and even though pipes are excluded dealer goodwill's critical to achieving anything).

£38 for the pipe (#1&2 are on one pipe, #3&4 on the other) and £38 for labour + VAT; they talked it up to over £100 by adding a can of brake cleaner. Who knew; works great washing diesel oil out of sound deadening "felt". I was pretty pleased with that so, again, tip-o-the-hat to Lloyds' in Aberaeron.

A little residual 'oil got left behind the foil-faced felt that sits over the turbo but heat chased that out over the following week and now we're good. Fuel consumption is looking promising too ... ;-))

Sadly they spotted wear on the rear bushes on both wishbones (not uncommon at 50k/miles they tell me) so there's another bill to come there too (still waiting to hear a fat lady sing; I'm guessing I'd better not hold my breath on that one?).