Volvo XC90 D5 2.4 Diesel, Limp Mode, P0101, Swirl Flaps, Injector Removal

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[@davesterl]

Find the items that are used on the Dave Sterl channel in the Amazon shop. www.amazon.co.uk/shop/davesterl

[@jamesnorton7453]

excellent Dave, I have one of these in Belfast how would I get in touch with you? I would really appreciate it.

[@chayannefernandes1]

Dave, short story long, bought a v70, same engine, same issues, you helped me alot! big hug

[@causelessharm4444]

Excellent video Dave. I'm an aspiring diyer looking to remedy an oil leak by the swirl flap arm. Having never done anything like this before, I've been looking for info on removing the injectors and intake manifold. This video is just the ticket, though I'm admittedly scared of what I'll find. Thanks for taking the time to put this together. Super insightful. Your view count will be jumping up as I watch this again and again.

[@zoros1976]

Just found your channel, great video of Volvo XC90 service and repairs. Own owner of XC90 and looking to do some repairs, so appreciated your content!

[@JHenry-vu8zh]

Great videos Dave. The attention to detail in your work is nice to see this day and age.

[@barrabadgesAust]

Thanks for this video. Got the swirl flap issue. I can now comfortably tackle it.

[@colinboyd4371]

Could watch this kinda stuff all night, thanks Dave.

[@dangerranger-in3kl]

Some job there Dave , and as per usual your punter gets to see the caliber and professionalism of your workmanship, which is second to none , great video , cheers , Ian 👍

[@davesterl]

Cheers ian, the punter is the first to see the video, shows them what's involved

[@jclark5456]

Nice to see work done properly by a professional, thank you for sharing.

[@davesterl]

Cheers mate

[@Liamautomechanic]

A lot of dismantling there Davy you've got great patience. Very good.

[@TheGibby3340]

Very nice indeed Dave...Your well equipped the tools and disposition for that job. First rate workmanship 👍

[@davesterl]

Hi Ian, yeah interesting wee job this with satisfying results. Car drives like new

[@catchyerselfoffgibbo8039]

Well done , a very informative and very well filmed video there, good camera work,

[@user-io2et5bv2s]

Very nice job and excellent video. Thanks. 👍🏻

[@125sm3]

Great job there Dave.

[@markholian3506]

Great job Dave, thanks for putting it all together 👍🏻👍🏻 - the video I meant not the Volvo - that was always a given 😁

[@davesterl]

Haha, cheers Mark

[@MarkGraham88]

Just found your channel by accident, brilliant videos, nice to hear a familiar accent on youtube! Subscribed.

[@davesterl]

Good man Mark. Are you a Norn Irn man then?

[@eldodos83]

Cracking job there Dave belt and braces as usual. She was running like a mouse chewing paper at the end! Have a later incarnation of the d5 engine in my volvo with sequential turbocharging, it's a great engine.

[@davesterl]

Cheers Robin

[@neil1482]

Well done. Would have loved to see the finished work going back in 👍

[@skinnyboob1]

Nice clean job done!

[@ENCASE]

Well done ... please do more VOLVO D5 videos

[@cptncurry5402]

Amazing work pal 🙏

[@remfernandez5310]

Nice job .. Great video

[@vanlifenomad]

Top man thank you, I now know what's wrong with an xc90 I've got in stock and how to sort it, cheers.

[@leonard1443]

Excellent video thank you

[@vodonnell1]

Volvo made it as awkward as possible great video.

[@bareenlars]

Super video! I am getting myself ready for this excact job and this video is great help! What was your method of cleaning the cox/soot from the intake and EGR valve? Best regards Lars

[@PaddyBoy644]

I’ve done that before all I did was dial it in degreaser and to get a large bottle brush cut the end off and put it in to a cordless drill and go to town.

[@harryhotspur3098]

Yer the man, excellent 👍

[@vygag]

To remove injectors way easier first heat the engine up (till coolant reaches 90 C), then start disassembling. Will save a lot of swearing and time.

[@warrenlewis7726]

Great vid, made it look so easy.... Even when the injectors wouldn't come out... No swearing or bleeding knuckles... Like I would. How much in labour roughly is it to that job? Looks beyond me... But I could pull all apart no problem just the putting back together!! 🤦🏻‍♂️😂

[@bapsmcginty4782]

I would have been swearing like a trooper half way through that job. Looked like one thing after another. Good vid to warn me away from Volvos. Nice work Dave.

[@peaandham1973]

Thanks for doing this video. I’ve a Euro4 D5 engine. There’s a slight leak at the rocker cover swirl rod end. The swirl linkage is missing, the arm that the linkage attaches to is also missing from the motor. Getting an air quality fault. Engine service orange triangle. I pushed the swirl arm down to open the vents. Been driving ok. Took off the centre hose today and found it caked in black tary soot. Not sure the best way to proceed. Plan to clean it all out, but where to go with the swirl situation? New motor and swirl kit as well? Thanks again for this video.

[@mechanicmatt871]

Great job 👌 your big slide hammer soon removed the tight injectors. Cheers mate

[@davesterl]

Aye matt, the number 4 that i filmed there was the tightest

[@simont930]

Did you reuse tjat injector or replace it?

[@the_retired_mechanic]

Not had the pleasure of doing that job. I have a taper thread cutting tool welded to a rod to remove copper washers but I do love your device. Not seen that before

[@ciaranmichaellidster]

Hi Dave lovevthe channel. I have an XC90 with the exact same issue. Can you recommended somewhere in Belfast to get fixed?

[@venomtailOG]

Next on my list of things to check are these swirl flaps and hopefull that will be my fault to my Volvo that I've been trying to fix for the last 2 years.

[@sagotremi6336]

Salut, super boulot. Mais avez-vous remplacé les brides et les vis des injecteurs par des neuves ? Car visiblement il faut les remplacer par des neuves à chaque dépose/repose des injecteurs. Merci. Rémi

[@chammysammy2513]

Hi Thanks for the video someday I'll do the same. Do you remember the diameter of the holes? Because I want to clean as you did with a brush.

[@BlueSky-bx5tf]

Hi Dave, didn't you have trouble starting the motor after you had the diesel lines taken off and the injectors removed? It must have gotten quite some air in the diesel lines. I did the same like you, but after I did put it all together, the motor doesn't start anymore. They talking about priming the fuel lines.

[@gubuzelaog]

Hi Dave .. I need to clean all the soot and carbon my XC90 like you have done on this video .. is it OK to clean inside the intake and exhaust valves on the head? If yes how?

[@Mr_Joeth]

Common problem in XC90 D5 is a broken ECU and injector plug cause misfire then go to limp mode.

[@pan366e]

Any link for the slide hammers used? Or the tread on the injectors?

[@tommydavidsen59]

My Volvo xc70 D5 starts then stops again. Do you know what might be the problem?

[@peterurquhart7191]

Hi Dave a great job 👍 but look’s a expensive job 😥😥how many miles has the big Volvo none ?

[@davesterl]

About 130k. Exact mieage is on the dash at the start of the video

[@andycalam9719]

Hi Dave, great vid. I changed the swirl flaps last year...soon after I noticed what seems to be the common D5 popping sound from the oil cap. I read that it is a vacuum issue (vac pump, mounts etc), but could this be caused by the gasket not seating correctly around the inlets? The car runs fine with good fuel economy.

[@davesterl]

Vacuum leak or pcv blocked

[@miccheck1516]

Do you want do another one of these? Not in limp mode but I’ve a small leak in the same spot.

[@chrishood1206]

mate, bought one of these just yesterday, thought id have a bit of a look at the motor, noticed the actuator arm was disconnected, i thought the closed position?? but drives fine with no fault code, there is also oil residue around flap arm,, im now stressing ive got a big bill ahead.. great vid though mate..

[@davesterl]

It won't set a fault code for the arm being off

[@alouisschafer7212]

So root cause was the boost leak at the swirl flaps and just a horribly dirty intake. I wonder if the EGR valve wasn't shutting properly. Swirl flaps leaking boost and an intake gummed up with soot from the EGR... classic D5 problems 😅Although this one was the dirtiest ive ever seen!

[@paulbolton8511]

Dave love the tool for getting the copper washers out do you remember were it was from cheers mate

[@davesterl]

No idea ive had it for years

[@mikerobinson7000]

laser tools Sold on eBay by the tool academy

[@aristidesdelgado8415]

Hola quisiera saber dónde puedo conseguir repuestos para la Volvo XC90 motor 2.400 diesel Estoy ubicado en Bogotá Colombia Muchas gracias

[@adamwiseman1906]

Hi Dave, im looking for an injector puller. Do you know what size you used to pull these out? Thanks Adam

[@mikeberry304]

Another cream job there Dave , carbon, dont we love e it , clean burning engines from modern day vehicles, had a transit custom yesterday 2018 , adblue showed 46 miles , guy from st Helen's, local dealers 6 week lead time for warranty repair , they told him it was a fault with adblue level sensor , £450 plus vat no courtesy van available, hire van nearly 500 quid a week , so he bought part , fitted it , 10 litres of new adblue , light still on ,I did a bit if research, vehicle must have forced regeneration of DPF, so I did that , scanner battery went flat aftet45 mins , van engine stopped, wouldn't restart , charger to verus , cleared failed DPF regeneration fault , started up , another 50 mins later regeneration complete , checkedadblue messages , now showing 10 litres in tank , mad as a box of frogs , what would we do without shared info on the internet and utube, hope all went well putting it back together and customer appreciates all you have done , cheers

[@davesterl]

Hi mike, good one that with the transit. I've heard that with the level sensors. I drove this volvo on an extended drive as the dpf will be sooted with the poor airflow. Punters dont see the extra hours we put into that. Yeah this one is a different car after this repair and clean out. Dont you just love the plastic moving wearable parts in cars these days.

[@mikeberry304]

@@davesterl had a scirocco 2.0 tsi brought on a recovery truck on monday , it hit a young deer in the south of england , driver said she drove to the nearest garage from incident, must have been about 75 miles away as engine is fried, plastic inlet manifold is melted , dipstick will not come out as its melted removed oil cap , stinks of burn , no compressions on any cylinder, spark plugs stink and are white, 59 plate car , gonna cost about 6 grand using 2nd hand lump , but I am not buying engine ,if she wants to go down that route she can pay for engine , not covered by insurance as it's her bosses car , she borrowed it as her car written off , so only 3rd party cover , so the deer is covered , but sadly not here anymore, people are idiots , would have cost a grand for rad pack and bumper , but now 6 plus using 2nd hand bits , engine bare 2 1/2 g on it's own mad , I am trying to get her to just buy him another car and draw back what she can for his , 61000 miles dsg box, black leather interior, big wheels , induction kit , but never been raced or rallied 🤣🤣😉👍

[@davesterl]

@@mikeberry304 nightmare. I guess it's between her and the owner. Car is written off effectively

[@mikeberry304]

@@davesterl told her shes got to make the decision, but unknown damages will be discovered when stripdown of old useable bits , what a silly girl , but I bet she has nice ugg boots and knows when her next false nail appointment is 🤣😂👍

[@wimvanhoof4903]

@@davesterl They should have made the swirl valves more accessible, not having to remove the injectors.

[@johnbrown5528]

Very informative video for that job dealerships quote £950-00

[@davesterl]

yeah, i wonder if they clean the manifold and all the intake tracts. that's the time consuming bit

[@chammysammy2513]

@@davesterl Hi Thanks for the video someday I'll do the same. Do you remember the diameter of the holes? Because I want to clean as you did with a brush.

[@christophernebauer2711]

That very informative wish I lived near you so you could fix mine no one around here has clue. Don’t think it’s swirl flaps as don’t have that noise . Car runs fine first ten ks then goes into limp with no boost. Very frustrating have already spend $1700 and still the same. Going to try cleaning the particulate filter.

[@charlesdale1462]

Assume your car is a D5 Volvo. Could be a turbo boost actuator, a common problem on this engine

[@stuartmcgarrigle6610]

Same here, changed flaps and still limping

[@isaackent2355]

Is there no alteration , as to make it impossible to happen again? I have one of these in limp mode, and no one can fix it, even the so called experts, all they want to do is replace everything until they find the issue, that's stupid though.

[@heisenfeis]

labour vise how long does this take? i might just get another car

[@goldbrick2751]

Hi Dave, great video, what is the littyle plastric lever that moves it, I am missing it on my car. Is it just a rubber band?

[@davesterl]

Its a plastic arm

[@causelessharm4444]

Swirl arm. A common break on d5s.

[@martinhann1672]

As the plastic ball on the swirl lap wears, the link falls off! There is a kit available which involves removing the ball and drilling an M3 hole to fit a new metal ball joint with link. Expensive and tricky to fit but is so much better than OE. The link comes from an RC model car, I think. There is a video too

[@HORNET6]

How many miles had this car done please? Nice job and great tooling!

[@davesterl]

About 110k miles. Might be able to see exact mileage on the dash at the beginning

[@HORNET6]

@@davesterl that little slide hammer you used to get the sealing washer out is sweet! Can’t find one anywhere 🙄

[@alfiemoon09]

Some yoke now!!!

[@davesterl]

Yes mate, different car now. Owner is over the moon!

[@alfiemoon09]

@@davesterl I'm sure he is. Some work went into that

[@richardheaton800]

Would this make the car lose power up a hill..and sort of stop if changing gear. Even if your foot is welded to the floor ?

[@salisburysteve]

Exactly this.. like the engine is choked.. Plastic arm will make it better - i don't know about the carbon build up or swirl flap actuator leak.

[@JLsAutoSolution]

Makes me happy that i don' t touch the european makes lol.. Nice video dave

[@HORNET6]

You know your stuff Dave so I’ll pose you a question; Since diesels are, stupidly, made to inhale there own exhaust leading to all this nasty build up, would you advocate‘turning off’ the EGR via the ecu so that it remains closed ?

[@davesterl]

I don't think it is stupid as the inert gases cool the cylinder. It is also illegal to alter the cars emission system

[@tvaatakt1]

@@davesterl NOx is nasty stuff that you don't want to breath. The EGR is there for a reason.

[@davesterl]

@@tvaatakt1 absolutely

[@HEGaming-pk2cd]

How did you actually clean the inlet manifold?

[@davesterl]

Power washer

[@mattyelder3616]

Is it not an issue if water gets in to the manifold?

[@tim62744]

Dave nice work where you located 🇨🇮

[@davesterl]

Its an Autel MS908p matey

[@simonrawle7885]

just seen the word flaps and had to click lol

[@chaosmagicification5770]

that engine was a sickly born engine, there is no way to fix this problem permanently it s gonna happen again.

[@davesterl]

Are you an expert?

[@chaosmagicification5770]

@@davesterl All D5s got same issue all around world. that means

[@liggen]

​@@chaosmagicification5770 I believe clogged DPF might be what's causing this. If you mainly drive short trips around the town, then taking a long trip every couple of weeks may extend the period between issue with the swirl flap.

[@chaosmagicification5770]

@@liggen I usually use volvo on the long journey, renault in the short trips. I add egr or injector cleaner every month apprx 1/ 5 full of tank. I ve changed that shity part 3 times. on this time working well but I know as well as my name its gonna happen again. That's why volvo's engineers changed this crappy design and switched to 2 turbos with different architecture

[@brushrescue1701]

EGR valves and these stupid Fanny flaps some of the worst things invented for this fucking engines 🤦‍♂️🤷‍♂️