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Discussion Starter · #1 ·
Hello everyone,

I'm new to the forum and would like to share my journey so far with you and hopefully get some useful info on how to proceed.

So I bought a used V40 D2 (2015, momentum) with 150k on the clock as my first car. Been satisfied with it untill after about 2k km when the first problems started to appear.

First I got a check engine lamp. Diagnostics showed faulty oxygen sensor (P014C if I remember correctly). At this time I also noticed some black smoke appearing when accelerating. Took it to a dealer in Zagreb, Croatia the next day. They checked the sensor, cleaned it, checked and cleaned the DPF, but the black smoke was still there, and they proposed to take it to the highway and clean it with high revs. They also updated the software and charged about 40 EUR total.

Couple of days after, black smoke still there, check engine appeared again. Second visit to the dealer - they checked the intake and the exhaust system, according to them everything is in the normal values, they can't find a reason. I told them about the possibility of defective EGR problem I found on the forums - but they checked it, cleaned and said it looks just fine. The only thing they had assumptions for was the turbo, and they quoted 2000 EUR for a replacement and service.

That was ridiculous for me and decided to take it to a turbo mechanic to take a look and possibly service it. He said the turbo was like new and he doubts that's the problem for the smoke and the CEL appearing. He proposed to blast the intake manifold and clean the DPF.

I went on my third visit to the dealer and forwarded the findings. They checked and cleaned the intake manifold this time, again were puzzled and doubted this was the problem. Told me the car was safe to drive. Cleaned the error and gave me the car.

At this time I had to move to Austria, which was the main reason I've bought the car. It was a 1000km one way trip. During the trip, the CEL ofcourse appeared again. The black smoke was always present, but a bit less than before. I decided to try a couple more kilometers to reach Innsbruck, but I was stuck in the middle of the italian Alps. All of a sudden I started to loose power at high speeds, then later in low speeds. When the car was under load - it just started shaking (both the cars and the revs). This was getting to unsafe to proceed to the highway so I stopped and called my trusted family mechanic. He told me to try and disconnect the car battery and plug it again in. I tried this for the first time and the car was like new! I've never felt that much power coming from the engine as that time I reseted the battery supply. With this "fix" I managed to do around 100 km and it started to shake again. Reseted a battery a couple more times just to reach Innsbruck and called the tow service there to west Austria- 600EUR.

The next day I barely came to the dealer in Austria and told them about everything. They proposed EGR and air filter replacement along with DPF cleaning and "burning?". Quote was 1600 EUR. I had no choice but to accept. I didn't have the garranty on the car and they weren't aware of the free replacement of the EGR. They also told me the car's EGR Cooler was replaced last year.

As soon as I though this is finally my last visit to the dealer, 100km after the repair - another CEL and black smoke. After calming my nerves for a couple of days, took it to the same dealer again. This time the code was oxygen sensor. They offered a replacement for 430 EUR. I accepted and the car drove well for a couple of days.

200km after the last fix there is still no check engine lamp, but the black smoke is still present and on my last trip to highway the car started to shake and loose power again on 110 km. Pushing the gas only makes it worse, and it's only a matter of time untill the shaking will appear on lower speeds.

This time I went to another mechanic, and his diagnostics this time tells me that an intake valve (Wirbelklappe?) is defected. Since I've done just 300km after the first major repair, I doubt they fixed the problem then and there was something wrong all the time.

I've lost all energy running around from one mechanic to another and really don't know what to do next - to push the dealer to fix it for free or to burn the **** thing. The car is turning to a nightmare and for me it's crazy to think that a car from that age and a supposedly reliable brand can be this unrealiable. The driving isn't satisfying anymore for me as I am just waiting for the next time the check engine lamp will appear. After giving almost 3000 EUR for all the service and having the problem still present, I feel like I'm being robbed.

Does someone have experience with these problems or/and has an idea on how to proceed?

Thank you for reading and cheers!
 

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All you've been doing is treating the symptoms, black smoke is a fault elsewhere which is clogging your DPF, wouldn't of said you've had continuing problems as it's seem to be the same problem all along and you're unable to track down the cause. It could be an issue with the DPF but it also could be an issue with what's causing the black smoke. Does the DPF light come on? I'd suggest taking it to a specialist that has good knowledge of the engine or a garage that comes recommended, cleaning the DPF is just kicking the can down the road for a while, it could be a defective injector or a sensor fault which is creating the smoke. With the correct technician knowledge and the correct equipment to read the information on the car would give you the best clue of what's going on. 2.0 D2 are decent engines and don't see no reason why it's shouldn't do another 150k as long as the correct maintenance is carried out and its looked after.

Jason
 

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Discussion Starter · #4 ·
Thank you for the reply Jason.

It's the 2.0 D2. I completely agree with what you've said about technicians not chasing after the main problem but rather treating the obvious symptoms temporarly.

It's weird how with the today's state of the art sensor and diagnostic technology the reccomended shops are not able to track down the root of the problem after multiple visits. I would be easy on them but they charge 170 EUR for an hour's work so this shouldn't be happening.

I guess I will keep lurking and try at another dealer.
 

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Yes totally agree. It could be a cheap fix or it could be an expensive fix, was it a Volvo dealer you went to or an independent dealer? A good independent dealer should have the equipment. I've seen it before where I live and fingers where pointing to the DPF without any consideration of what may be causing it in the first place. Good technician are hard to come by especially ones that you can trust. Hopefully someone will be along soon that can be more help than me and please keep us informed of how it goes.

Jason
 

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diagnostics is a skill, but also you need the right kit. long story short... A "snap on" scan revealed my C30 dpf pressure sensor erratic, air meter dead, and eloys fluid empty. after a while of getting no where, and the initial cost of air meter and pressure sensor (removed, cleaned up and sent back) (sorry) an independent Volvo specialist scan showed simply the fuel pressure was high. new fuel filter fitted, no problems for the last 20k
 

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Might be worth a try, but what diesel do you put in the car? Could you perhaps run 1 or 2 full tank of Shell (or whichever is the premium fuel supplier there) most expensive diesel (Vpower?) to see if that can help clean up the internals of the engine?
 

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Discussion Starter · #8 ·
I don't have a preference for the brand of diesel, but my last fill was actually from Shell. I've also been advised to clean it that way and told the smoke will go out after 50-100km but it didn't. Also, they have checked the intake and exhaust systems and filters so I don't know if it needs cleaning.

Update from the workshop: on first look they assume it's "wirbelklappe" - swirl flap? They will take a detailed look and let me know through the week. I am no expert and don't know the exact use of this part but I doubt this could cause the smoke and the power chugging? Also, why is it appearing just now on the diagnostic?
 

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Excessive Black smoke from a diesel is indictive of one of two things. Not enough air, clogged/restrictive air filter (easy enough to check, but that won't cause it to burn clean then go "black exhaust" in a random pattern, it's either clogged or it isn't). Not enough air could be a boost leak. again doubtful. But still a good idea to check all boot connections and such for a leak. The 2nd area that causes "black smoke" is over fueling. too much fuel for the air introduced by the intake turbo. I'd have these "technicians" start looking at your fuel system (again doubtful with your description of how it runs after re-setting computer by connecting/resetting computer). I believe you're looking at an ecm/wiring (intermittent open/short?) problem more than anything.
 

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Sorry to have the problems with your car. As already guys said - this could be cheap problem to solve. I had S60 d5 previously, appears the same issue - sudden loss of power and black smoke (I thought i was running on coil engine). I had a mechanic, an experienced Volvo specialist - he fixed it for 20€ - the problem: a crack in the intake just pass the MAF sensor. When testing a car in idle revs, nothing showed as the crack was too small to induce false MAF (mass air flow) readings, but when tested at load, the intake seeks for any possible to suck out maximum from the air filter, but when the crack gets loose, it gets more air to the system with readings from a MAF sensor to x mils, while in reality it gets xx mils. The ECU do not know the readings are false as it gets more air, the air-fuel mixture is compromised.
 

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Discussion Starter · #11 ·
Thank you all for your replies.

Update after my last visit to the "experts" - after their inspection of injectors and overhauling the swirl flaps they still have no idea where the smoke comes from.

They took it for a 50 km spin and everything seems fine to them. Didn't charge me, but told me upfront the smoke is still there and advised to take it to the Autobahn. I filled it with Shell Vpower and took it for a spin, after some city driving and then onto straight roads, I noticed really intense black smoke when I "push it". Driving for long periods on high revs and trying to clean it didn't help, because at the end the smoke would still be there when I accelerate hard (or starting from a stand-still, first, second gear...). It has come to I point where I am having serious power loss again and it is not safe to drive.

I am considering the possibility of a crack in the intake, and the false readings of the air-fuel mixture. Is this something I could possibly check on my own?

I have written to Volvo HQ about the behaviour of the dealer and am looking for reliable mechanics in Voralberg, Austria (I'm open to suggestions).

Once again many thanks for all of you. If it wasn't for such a helpful community I would completely lost my trust in the Volvo brand and the V40, although I am on a good path for loosing it regardless.

Cheers
 

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Thank you all for your replies.

Update after my last visit to the "experts" - after their inspection of injectors and overhauling the swirl flaps they still have no idea where the smoke comes from.

They took it for a 50 km spin and everything seems fine to them. Didn't charge me, but told me upfront the smoke is still there and advised to take it to the Autobahn. I filled it with Shell Vpower and took it for a spin, after some city driving and then onto straight roads, I noticed really intense black smoke when I "push it". Driving for long periods on high revs and trying to clean it didn't help, because at the end the smoke would still be there when I accelerate hard (or starting from a stand-still, first, second gear...). It has come to I point where I am having serious power loss again and it is not safe to drive.

I am considering the possibility of a crack in the intake, and the false readings of the air-fuel mixture. Is this something I could possibly check on my own?

I have written to Volvo HQ about the behaviour of the dealer and am looking for reliable mechanics in Voralberg, Austria (I'm open to suggestions).

Once again many thanks for all of you. If it wasn't for such a helpful community I would completely lost my trust in the Volvo brand and the V40, although I am on a good path for loosing it regardless.

Cheers
I was only thinking this morning how you was getting on. Sorry to hear you're no further forward and at a loss for ideas. This isn't regular behaviour from a car of this type and suggest you're probably very unlucky, if it's any consultation I've had my share of rubbish luck with my other car.

I'm very surprised no one can seem to diagnosis the issue so at least you could start moving forward. Please continue to let us know how things pan out and sorry I can't bring nothing else to the party.

Jason
 
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