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Discussion Starter #1
Hello Forum,

Simple and straight forward i got a single random hiccup in my MY2015 V40 D4 190hp. Feeling says it seems like it has something to do with boost or fuel. Only below 3000rpm
Ill try to explain it the best i can;

When rolling at 1200 rpm for example and i accelerate with lets say 50% throttle, the car accelerates towards 2500 rpm the boost starts to build at 1600 rpm something, i feel the boost building and when the rpm hits around 2000 i feel a hiccup(max boost?). It is only 1 single hiccup in the lower rpm, it never happens twice in the same pull. And never above 3000 rpm(because max. boost is in the lower rpm?) The rpm it occurs is not always the same but it only has happened between 1700 and 2500 rpm as far as i have tested recent weeks/month.

The hiccup feels like a fuelcut or misfire, but only occurs when building boost or hitting full boost(which i think is full boost, no gauge), when doing less throttle and moving towards 2500 or more, i dont feel the boost hitting like expected but also no hiccups. so only under boost.

When driving at highwayspeeds around 2000 rpm, and accelerate moderate i also feel the boost building and than the boost all of a sudden is less, but not gone. its not rpm dropping but you feel the "G-forces dropping"- and after the drop it stays that way. You only could feel te difference. The feeling is like a BOV is opening.

Full throttle pulls fine, whole rpm range, no hesitation and the boost feels good. Only hesitates on lower trottle input while boosting.

Went on holiday to Austria and drove 600 miles through germany, when going uphill at something like 70-90 mph(on cruise), the car does hesitate back an forth all the time, so something like boost-nope-boost-nope. Like it cant hold boost at constant or moderate trottle when the engine loads are more since moving uphill. At the time it happens it is fixed by giving some more trottle.



Since the D4 is a sequential- or bi- Turbo i looked at the exhaust bypass valve and wastegate valve, both seem to open fine. the turbo bypass valve actuator (small to big turbo) can be opened without help of a vacuumpump, by that i mean i can open the valve by creating a vacuum by sucking on the vacuum hose comming from the actuator. The compressor side does not have a blowoff valve but a check valve between the big and small turbo, which is operated by a spring, dont know exactly how this works or could cause my problem.

Things i dont think is the problem but could be.

  • boost leak, because full boost is fine
  • turbo wastegate and bypass actuator, also replaced both turbo boost actuator solenoids
  • vacuum leak, dont think so, runs fine besides the one single hiccup
  • EGR, since its software-removed and actuator unplugged
  • The car is remapped, since the tune this problem really occured, went back to the tuner and he said everything looked fine. Not hitting torquelimiter or something. Mate with a D4 also remapped at the same guy same day and does not have any problems.
  • fuel should not be a issue, full trottle is fine and reaches maximum rpm well. Or is the max fuel pressure at max boost?
What should i check?
- throttle body sensor? Or more like a sensor like a lambda? Maybe injector? No error codes found, scanned by the volvo dealer.

Its really weird because it only happens once in the pull of that gear, and only when pulling/medium boost. Not like it happening all the way in the rpm multiple times or at full.


Thank you.

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Had this issue on my v40 d4, it was the t-map sensor on the intake that was bilen. Changed it, works fine now. Hade to do something in VIDA too, I dont remember tho..

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Discussion Starter #4 (Edited)
MAP-sensor is replaced 4000 miles ago for a Bosch replacement, which is the main sensor supplier for volvo. So cant be it right? Looks pretty clean too. What was the VIDA thing?

Also it had a new intake manifold 4000 miles ago with new swirl flaps. Installed by the dealer. After that i replaced the MAP sensor myself, cant recal which brand though.

Turbo boost solenoids are swapped with a replacement from a D4 with 60.000k miles on it. Mine has 100.000 miles or 170.000 kilometers.


Is there a way to clean turbo boost sensor?
Or is MAP sensor the only boost sensor?

EDIT: found out between both turbos there is a sensor too, with a large tube to it, should be OE 31319419 which is a exhaust pressure sensor, i added a picture, should be save to unscrew the sensor from the tube? Or couldnt this be the problem?

Today i go the hiccup twice in the rpm range in a pull, also turbo seems to kick in too much on less throttle.
I also tried to do a highway pull with the cruise control buttons instead of using the throttle, so i just bash the + symbol multiple times when driving 60 mph, so i bash it till the cruise-display says 80 mph. Car hiccups alot when it tries to reach 80 mph too, like it wants to boost-not-boost-not-boost.

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Discussion Starter #5 (Edited)
today i removed exhaust pressure sensor, not clogged up but cleaned it anyway, also the line which connects the sensor fine, i could blow some air through it. problem stil present

so far:

  • Changed Boost control solenoids ( both )
  • check wastegate and turbo bypass for working
  • No vacuum leak found
  • turbo exhaust pressure not clogged up
  • EGR is software and physical disconnected, no plate tho.
  • tommorow testing for boost leaks. EDIT: everything seems fine.
so could it be the tune? a friend has same car same tuner no issues
 

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What tune do you have? Chip/box maped ecu? Some time if its overtuned and The dpf is still on will you can get symtom like that.....
 

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today i removed exhaust pressure sensor, not clogged up but cleaned it anyway, also the line which connects the sensor fine, i could blow some air through it. problem stil present

so far:

  • Changed Boost control solenoids ( both )
  • check wastegate and turbo bypass for working
  • No vacuum leak found
  • turbo exhaust pressure not clogged up
  • EGR is software and physical disconnected, no plate tho.
  • tommorow testing for boost leaks. EDIT: everything seems fine.
so could it be the tune? a friend has same car same tuner no issues
has anyone checked the fuel pressure as it could be a week pump.
 

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Discussion Starter #8 (Edited)
What tune do you have? Chip/box maped ecu? Some time if its overtuned and The dpf is still on will you can get symtom like that.....
Its remap, went back to the tuner and het said there whas a code shown up, not in the ECU but in the ECM or something?
code P0471, he did a reset and i went for a drive around the block. he scanned the car again and again a P0471.

so after some research indeed exhaust pressure sensor out of range/high voltage or something. so i ordered a sensor, and boy those are expensive.
sensor should arrive today(EDIT: in a few days because of corona), ill try cleaning the tube it sits on and will report back if it did anything.
EDIT: The tube is impossible to reach on the turbo side to take it of the car, so i tried cleaning it ON the car, its not blocked for sure.

if not, you could be right.
 

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I had similar issues with my 2014 D4 and for maybe any reference I will share my story:
It was straightaway after a remap. Highway speeds of about 120km/h, accelerate with 50-60% throttle and I got a hiccup around 1900-2000rpm. Full throttle was not giving any issues :p
But I received a "power loss" message with a turtle. Went back to the tuner, they told me there was nothing wrong, reloaded the tune and send me off. On the way back it was still occuring. The tuner decided to create a new map but in some sort of other way. They told me the car was hitting some torque limiters but it wouldn't throw any DTC errors.

Via which tuner is your V40 remapped? Maybe by any chance it's the same tuner and the same issue?
 

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Discussion Starter #11
My Car is tuned by GJ Mensen in Holland. I dont know what software he uses but its from germany as told.

Today swapped the Exhaust Pressure Sensor, pulled the Battery to reset the car and drove a few miles: car feels smoother, at first no boost/very late boost, tried to drive a few miles on cruise to let the engine adapt to the sensor.

So end of story, stil the hiccup, but doesnt feel as bad as it whas before. Looking into DPF pressure sensor and contacting the tuner for the 4th time to look into it again.

@Reinberto did he fix it with software?

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So your tuner just loaded a standard tuning file? Is he able to make changes to it?
If he cannot solve it, I would ask him to load your original software again, and ask your money back because such behavior is not acceptable.
After that, contact volvotune.nl for a good tuning. Or you can visit a good tuner in Belgium when the border is open again.:)
 

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Discussion Starter #13
Indeed standard software loaded onto it, dont know if he can make changes. Also i have contacted volvotune.nl to look into it but he wants me to take the car to him with original software

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That is why I have chosen a tuner who writes the tuningfile himself. If anything is not working as it should, you can always go back and corrections can be made.
I was first planning to go to volvotune but because of the distance to NL and the discount at APEC I finally went to APEC.
Good luck to you, I hope it can be solved soon.
 

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Discussion Starter #15
So contacted the tuner, wednesday i have appointment to get into it, told him if he couldnt fix it next week i would like to pay him for the service and he should give me back the money for the tune and remove it. After all i drove with the tune for nearly 2 months but im tired of the bullshit. Maybe its the car since a friend of mine drives with the same tune and no problems whatsoever, but im sure Volvotune can help me out, if not with a better tuner or finding what causes the issue.

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I have had the same kind of problem with a '15 V40 D2 2.0. Got the car with ca 1K km on the clock and a remap. At 130k kms it the hiccup started around 1300 rpm so it only happend at slow speeds (driving around the city). Got to the original tune but did exactly the same only less noticible cause of the lower available torque than the remap. Drove around with it for a little while and it was gone when the EGR was replaced. After that it only happens occasionally. Still gong stoing strong at 235K

Edit: Only now i see you have a disconnected ECU. Last years air intake recall also fixed it for me for a while.
 

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Discussion Starter #18
I have had the same kind of problem with a '15 V40 D2 2.0. Got the car with ca 1K km on the clock and a remap. At 130k kms it the hiccup started around 1300 rpm so it only happend at slow speeds (driving around the city). Got to the original tune but did exactly the same only less noticible cause of the lower available torque than the remap. Drove around with it for a little while and it was gone when the EGR was replaced. After that it only happens occasionally. Still gong stoing strong at 235K

Edit: Only now i see you have a disconnected ECU. Last years air intake recall also fixed it for me for a while.
If you mean disconnected EGR, indeed. but stil want to make a block-off plate for that. so its 100% closed
 

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Discussion Starter #19
Sounds good!
Today the tuner just took the car inside, not a alot of talking. came out 40 minutes later- after a testrun- with money and some papers, he brought the car back to stock and gave the money back, so really nice of him. he said he did more than 50 of these D4's and had no issues reported, i should be the first one. Now waiting for a response from Volvotune.nl to get i remapped. fingers crossed and will report after the remap has done propper!
 

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It looks like your tuner is an honest guy.
Good luck at volvotune. I know that they do a pre-check before tuning, so if something is broken, they might find it.
Good luck and keep us updated. And enjoy the "standard power and torque" again...:)
I just checked volvotune: they tune to 235 hp and 470 Nm. Not bad at all!!
 
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