Volvo S60 2.0T Barge-O-Matic

Volvo S60 2.0T Barge-O-Matic

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Otispunkmeyer

Original Poster:

12,597 posts

155 months

Wednesday 17th June 2015
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So I'd had my old R-reg Volvo V40 for just over a year and had been meaning to get rid of it. Being me, I just couldn't decide what to replace it with. We started with possibly getting a new Aygo on PCP, then moved to a Fiat 500 used for around 5-6k. Then moved on to Fiesta TDCi's for the same price as it seemed like a better long term bet with diesel economy and some niceties like cruise control. Inevitably though, I went for my favourite searches on AutoTrader; Petrol, Auto, <£2k and found this:

IMAG0473 by Alex Mason, on Flickr

IMAG0475 by Alex Mason, on Flickr

IMAG0474 by Alex Mason, on Flickr


Its a 2004 Volvo S60 2.0T SE with a 5-speed auto and some other choice options such as rain sensing wipers and auto-dimming review mirror. In-fact its got all you could ever want really; electric front drivers seat with memory, arm rest, cruise, heated seats, heated mirrors, flippy key, a button to control the "coming home" lights from the key, leather seats and probably one of the best OEM branded stereos I have ever heard (Volvo HU-803).

The 2.0 Engine is a 5 cylinder unit, supposedly with 5 valves per cylinder (though I may be wrong there). The turbo is only a light pressure one, giving up 180 HP and 180 lbs-ft. So its not quick, but does make smooth progress. It was the first car I saw and I bought it. Something about it just said, "you will not find another one like this for this price".

I paid £1400 for it. Now for that price you might think there maybe some catches. However, the bloke I bought it from (a nice Srilankan who even called me back when he realised I had over paid him to arrange giving me it back!) was only parting with it because he'd had another child and now there weren't enough seats. Weirdly he even gave me £50 off without even asking because the MOT is due in a few months. This set alarm bells ringing; "Did he want to get shot?".

Well if he did, he went the wrong way about it. In the past year it appears to have been serviced about 3 times. Cambelt? Done. ATF? Done. Brakes alround? Done. There are a fat wad of receipts from a local Volvo specialist for all the work and more. All it needed immediately were 2 new front tyres (nearly bald and mixed makes) and an AirCon regas (yes really just needed a regas!).

Its done 77k miles and even the leather on the seats is in perfect condition. None of that nasty wear on the drivers seat side bolster. Paint is in fantastic condition for the most part. There is a patch missing off the front bumper and a bit of bubbling under the paint on the roof line, but that aside there barely seems to be a blemish. Its remarkably free from stone chips too. It drives straight, brakes straight, there are no rattles in the interior, its extremely hushed on the motorway, it kicks down eagerly, changes smoothly and the engine pulls well through its torque band. I can't believe you can get a car this solid, this refined for less than a decent TV.


There are a few things which need attention but I think they are only minor (unless I get told otherwise!):

Headlamp electrical connectors seem a bit flaky. Had a Bulb Out Warning, but was just a loose connection. Checked the other side and that seems to be missing its plug altogher! Just bare spades on the bulbs prongs. The bulb retaining clip is bent as well so it doesn't hold the bulb securely. Not sure how that has been managed.

Alloys: Front alloys are kerb damaged quite bad and a lot of the paint is flaking off the spokes. Alloy wheel refurb is easy enough.

Handbrake needs looking at. On a hill, if you pull the HB, then let off the foot-brake, the car will roll back a few inches before the brakes catch it. Something is not quite right there.

When wafting about, when you are coasting and then getting back on the throttle, if you are a bit abrupt with it you can hear a small clonk as the transmission engages. Probably a bearing or worn joint there that needs seeing to.

Brake judder. Only sometimes, the brakes judder. As they are not very old I doubt they have warped. A few hard stops from speed seem to have made a significant difference so I suspect this is residue on the discs from the car being held on the foot brake a lot.

Power Steering. Seems to pulse slightly at half lock, especially when you haven't got any load on the engine. Likely just needs a new pump. Can get one for not much and doesn't seem a difficult job.

Engine: Seems fine in general, valve gear might be a bit noisy when cold but thats just an age thing. However, under acceleration the engine does sound like it has "whine". I am not sure if this is just how it sounds or there is a bearing on its way out. If I had to describe it, it almost sounds exactly like a roots-supercharger! Its quite a nice noise to be honest, but I am aware that there isn't anything in there that should be making such a noise!

All in I think I have gotten a bargain here. Its clean, its straight, its been well looked after and there are only a few jobs to do on it. So very pleased with it. Already had it on a long jaunt and it is just effortless. Such a pleasure to drive.


Otispunkmeyer

Original Poster:

12,597 posts

155 months

Thursday 18th June 2015
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Fuzzarr said:
Had a read of this this morning and enjoyed it. If I was after a relatively spacious, solid and dependable motor with a bit of class for peanuts I'd be all over one of these. The D5 appeals but petrol must be more fun.

Looks like it's doing well after 11 years and has lots of life left in it. I've read nothing but praise for the stereo that came on SE cars. smile

Edit: Interested in more pics, especially interior details, if you have them. Does it have a massive boot?
Here you go! Boot isn't super large, but its big enough for what little I put in there. I do like that it has a foldy up portion that lifts up from the floor on hinges. Then it has elastic material so you can secure items to the floor or to the foldy up bit. I also like that there are release handles just behind the lamps that let you unlock and push down the rear seats so that you don't have to go round to the passenger doors and do it there. Volvo. Like your dad, always thinking.

IMAG0479 by Alex Mason, on Flickr

IMAG0478 by Alex Mason, on Flickr

IMAG0477 by Alex Mason, on Flickr

IMAG0476 by Alex Mason, on Flickr

Garett said:
Otispunkmeyer said:
Handbrake needs looking at. On a hill, if you pull the HB, then let off the foot-brake, the car will roll back a few inches before the brakes catch it. Something is not quite right there.
Thats a feature not a fault I believe. I've had my D5 for 4 1/2 years and its always done that , even after having the rear brakes overhauled at a local Volvo specialist.

They are solid and very well put together. They seem to be easy to work on too and everything is laid out in a logical manner. Mine has clocked just over the 178k mark today and seems happy to plod on for the same again. The suspension components like bushes and ARB links seem to take a hammering on these but just keep on top of the maintenance and use decent quality parts and you won't go far wrong.
Reading round on forums it appears you are right! Countless threads about the car rolling on the HB. Something to do with the design of the integrated drum they use for hand brake duties. Though it is still disconcerting as you can witness the calipers moving/rotating about the axis of rotation as well.



As for the engine. Its nice. Its very smooth and basically just disappears when on a cruise. As said, its not the fastest thing in the world. Light pressure turbo (about 8psi), autobox and a weight of 1600+ kg means the 180 HP has a lot to do. But it gets up to speed nicely and has some decent mid range guts if you need to adjust speed mid-flight. But yeah, its one for lazy wafting rather than foot flat antics. There is just a hint of 5 cylinder woofle, but from the seat you're hard pressed to hear it really. Its distant. At 2 liters its probably not large enough to make itself known on the sound front!

Edited by Otispunkmeyer on Thursday 18th June 08:53


Edited by Otispunkmeyer on Thursday 18th June 08:59

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Thursday 18th June 2015
quotequote all
Gad-Westy said:
Just parted company with out 2.0t S60 a couple of months ago. Was a very dependable and comfortable wafter.

The 2.0t engine is quite a strange lump. It's very smooth and actually does a good job of getting the car along at a decent lick but it always seems such a lazy engine in terms of response to throttle. The Seat Leon 1.8T that our volvo replaced had a forced induction engine with the same power output but the delivery was entirely different, far more responsive but way less refined. I guess that is deliberate as it does make for smooth progress in the Volvo.

The handbrake thing you describe is normal. And I definitely agree about the stereo, vest car stereo I've had by a mile.

Got to ask, how do you find the steering lock? It was ultimately the main reason my wife and I got rid of the Volvo after a year or so. We have some fairly small mini roundabouts and other pinch points locally and the lack of lock started to really start to grate. Great car generally though.
Oh yeah! Its probably the only really annoying thing about this car. The turning circle is abysmal! Went to the shops with a friend the other day and for the car park, you go in then have to do a 180 back on yourself to get to the spaces. Being used to the Civic, I didn't prepare and ended up having to do a 3 pointer to get round!

This will not be a car I take into multi-stories often!

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Thursday 18th June 2015
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kapiteinlangzaam said:
The PAS judder/pulse will likely be an internally broken rack - quite common on these cars.

New rack is the only solution. £600+ even using 2nd hand parts an indy to fit (need to drop sub-frame etc).

Good news is you can drive it like that basically forever if you are willing to put up with it. I did 30k miles in my V70 of the same vintage with the same problem.
Worrying! but at the minute its really not noticable. Only notice when cornering, about half lock, with no throttle/coasting and even then it can be difficult to tell if its that or some rut in the road (Terrible roads round here).

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Friday 19th June 2015
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Little update

Got some replacement headlamp bulb retaining clips and new club holder plugs to replace the dodgy ones currently there. Will be interesting to try do this without removing the headlamps!

Whilst investigating this though I have come to the conclusion that this thing has probably had a decent prang on the off-side and its been repaired. The evidence is thus:

1) missing bolt for fixing the wing to the front of the car just under the A-pillar (noticed this the other day, but it still feels all solid)

2) hot snot or some kind of epoxy resin glue is visible when looking down on the bumper where it mates under the headlamp. I am guessing this was used in place of now broken retaining clips and or misaligned/enlarged retaining clip fixing holes.

3) Wheel arch liner on this side is affixed directly to the lip of the wheel arch on the wing. On the other side its affixed somewhere behind this lip.

4) Headlamp on the OS is missing its headlamp washer rest and is actually mounted/positioned slightly lower than the NS headlamp. Headlamp glass looks newer and it does look like the rubber seals/gaskets on the lamp have been roughed up from the process of removing and replacing the lens.

To be fair though, these things are really only detectable if you go hunting. It looks like its been an honest repair job and I think whoever did it has done it will. Everything is solid, nothing is flaky, its just slightly out of straight. This will explain, probably, why the previous owner had a brand new radiator fitted. It was either fitted as part of the repair or was something that let-go early due to the crash damage, but was OK at the time of repair.

Not too disappointing really. As I say, drives and brakes absolutely arrow straight so mechanically its good.


Back on to this hand-brake roll. I gather it is normal, however I think mine rolls a bit too much and I got the OH to watch the back wheels when I put the HB on on the driveway and watch it roll back. Apparently the callipers move as well. They rotate back a few degrees.

Should that happen? Worth getting it looked at?

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Friday 19th June 2015
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Also here is a short video of me revving it on the drive. Can you hear that sort of dull, supercharger-esque whine? Not sure if that's just how these sound of whether there is a bearing for one of the pulleys on the engine that's crying mercy!

http://1drv.ms/1Ip4Ytj

It's a one drive link.sorry.

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Wednesday 24th June 2015
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Bit of an update.

The engine has started to idle a bit rough on a morning or after being left for a long time. It often coughs into life, then runs rough. A few blips on the throttle sorts it. Having read about Volvo and their duff ETM (electronic throttle module) I have come to the conclusion that the electronics are fine, but the throttle valve assembly likely needs a bit of a de-gunk. I guess once its all cooled down and sticky crap has condensed and settled, the airflow is restricted just that little more at idle throttle. That or the throttle gets a bit stuck at its closed position. But I hear the motor for the ETM is quite strong so not sure its that.

Anyway, had a look at cleaning it and of course, on my particular car the damn thing is buried under the manifold....


Secondly, that whining noise. Having perused YT for S60 2.0T acceleration videos, it would appear some do and some don't have this whine. The differentiating factor appears to be whether your car is manual or automatic. The latter whine, so it must be a characteristic of the 5 speed auto box.

Third. The clonking noise when setting off or getting on the throttle is likely down to the axel bolts on the ends of the shaft. This is located behind the centre caps on the wheels and to test if that is the problem you simply tighten them up having put on a little loctite. Apparently these un-torque themselves quite easily and causes some slack to appear in the shaft assembly. The permanent fix is to use similar bolts off of an XC90 which feature a rubber washer/gromet which stops them from vibrating loose.


Otispunkmeyer

Original Poster:

12,597 posts

155 months

Thursday 25th June 2015
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kapiteinlangzaam said:
Otispunkmeyer said:
The permanent fix is to use similar bolts off of an XC90 which feature a rubber washer/gromet which stops them from vibrating loose.
That advice has been superseded in the last year or two.....

The rubber washer bolts were trapping water and literally fusing the whole hub together in one mass of rust. Very, very expensive to sort!

I dont know about the UK, but Volvo here in NL wont even sell you the rubber washer bolts for the '90 anymore, and new wheel bearing kits from Volvo come with normal bolts.

Best thing to do is replace with new, original bolts with loctite. They are stretch bolts and can only be used once, hence re-torquing the ones you have on there is not a permanent solution.
Noted! Will get some. Just as well because those XC90 bolts were ridiculous in price. A few quid for 2 bolts was suddenly £18 ea for a bolt with a thick rubber washer!

I will re-tighten the current bolts, just to see if that actually is the problem. If the sound goes away, then I shall get some new bolts and replace them. Do you know if Volvo sell a replacement ETM with a contactless position sensor? So far I have only seen people splicing in a a third party contactless TPS into the existing ETM.


EDIT: Starting up again this morning, I am now not so sure it is the ETM. The car starts and it is lumpy. A rev up and it really sounds like there is a misfire/bad timing/cylinder out. After 2 or 3 squirts on the throttle though its fine, but then the engine sounds rather loud and blowy whilst reversing down the driveway. Really not sure whats happened since I bought it, it did not behave like this.

Still worth cleaning the ETM out? I should probably double check coils and spark plugs as well.

Is it a possibility that a petrol injector is sticking shut on first start?

EDIT2: Further sure the ETM is probably ok. This is a 2004 car so doesn't have the ill-fated Magneti Marelli ETM, its the simpler more robust Bosch unit. So now I am looking at Spark plugs, Coils, Injectors and the MAF.

Edited by Otispunkmeyer on Thursday 25th June 09:11


Edited by Otispunkmeyer on Thursday 25th June 10:23

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Thursday 25th June 2015
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Hoofy said:
I swear I posted this here but coilpacks. Check the coilpacks. Are you not getting a fault code? Mines displayed similar problems over the last month - and started throwing up an engine error. The scanner said it was cylinder 3... coilpack died. Apparently, a common issue.
No error messages as yet no. I keep getting one about the alarm, which again I gather is common fault because of where the alarm is positioned. Not too worried about it. But thats the only message I get, there are no more. Perhaps its only just starting to go? Once its generated a few HV pulses its sort of alright again.

How can you test the coils to check if they are dying? Having said that, could be the HT leads as well.

Reading around...a duff coil has symptoms exactly like I have. I am, perhaps too hastily, ruling out spark plugs as I have found a service receipt showing that they had been replaced in the last two years. Though thats not to say there were replaced with something decent.

Edited by Otispunkmeyer on Thursday 25th June 14:46

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Thursday 25th June 2015
quotequote all
Once things like that start to go, I don't think it takes long. The EM stress from high voltage will soon wear down any s in the insulation etc.

Mine is literally only faltering on start up when cold. subsequent start ups seem fine and even today when I went out for lunch it started fine. It starts first time, like you would expect but on a morning it just comes out all lumpy and once it does get going, is significantly louder for a minute or two before becoming right as rain.

Casting my mind back a week or so I had noticed this occasional hiccup out of the blue on one morning. Then it never appeared again. Now its doing it every morning. So I am definitely on the downward trajectory here. Odd though that its doing it cold, rather than hot, where you usually get ignition system issues.

Still, changing a coil pack is a damn sight easier than fannying around trying to get at the ETM!


Edited by Otispunkmeyer on Thursday 25th June 16:36

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Thursday 25th June 2015
quotequote all
Dammit this is a car forum. Everyone should have a beard. And sandals.

Otispunkmeyer

Original Poster:

12,597 posts

155 months

Monday 29th June 2015
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Nothing came up when my indy got his OBD scanner on it. I think if there is a problem you do eventually get one on the dashboard too. I think its a short lived thing that clears before the fault can be generated.

Having said that, they pulled all the coils and plugs. All the coils appear to fire fine but cylinder 5 spark plug was mucky (whereas the other 4 were fine). So something isn't right somewhere. I'll keep an eye on it. They cleaned up all the plugs anyway and I have not had the starting issue since, so its very likely ignition was the cause. I'll likely order a new coil and a set of genuine spark plugs (apparently volvos are fussy here).

On the way home, the boost pipe blew off. Which was interesting! without any boost at all the car goes nowhere! Fixed it back on and took it out with my bluetooth OBD thing and the torque app. Shows 6-8psi of boost with peaks of 14 (which I don't trust to be honest). So about right for a low pressure turbo.

Strangely they said the manifold boost pressure sensor was reading way off, even with the engine off (ignition on). It was reporting 145 psi! Not sure what to make of that.

New power steering fluid has properly sorted the steering now. So thats good. They couldn't see anything wrong with the handbrake, so I guess thats just how it is.

New axel bolts + loctite have solved the clonk on power take up but there is now new clonks when hitting speed bumps. I am going to assume drop links. Its a heavy car and the roads round here are worse than the surface of the moon, so I am sure they're taking a battering. Will sort out some HD drop links in the near future and a set of new bushes.

Got the tow bar removed, which was a heavy fker! The back of the car now sits a bit higher!