Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Apologies for this being so long but I want to be as comprehensive as possible, not least to avoid putting well-meaning forum contributors to unnecessary efforts in trying to help advise me on things that have already been considered.

Car: 2016 VOLVO XC90 2 (256) D5 AWD 224 CV. 115,000 km (71,000 miles) In France

Problems:

1. Significant lack of power. Acceleration is much slower than is usual. Car will only overtake much slower vehicles either on the flat or downhill. Uphill, speed decreases and the gearbox changes down to third while revs climb slowly to a maximum of about 3500 rpm, without changing up a gear. Driving manually makes no difference. If I change up to 4th while uphill, speed drops off.

Even while driving on the flat, If I press hard on the accelerator nothing happens for just over a second. Nothing at all. The revs then rise very slowly.

2. There is a single error read using my OBD2 reader. P2262 “Turbocharger/Supercharger Boost Pressure 'A' Not Detected”

3. Vastly increased fuel consumption. Even with the very lightest right foot (not that a heavier foot makes any difference) I am averaging 12.4 L/100km or 23mpg imperial even when driving at around 90kmh or 60mph. I have not once bettered 11 L/100km (25mpg) since this problem arose 6 months ago.

4. Traces of soot around exhaust pipe tails. Nothing too bad. No obvious signs of smoke.

What has been done:

The car has been at my local Volvo dealer 4 times in an effort to resolve the errors. 2x “diagnostics” including smoke test.

Volvo

first changed the EGR valve and cooler. This did look to be stuck when the vacuum hose was connected to a pump but I was mostly relying on the Volvo mechnic’s word that it had failed.

I was advised that the next step would be to clean the inlet manifold. The quote for this was ridiculous so I removed the manifold and did it myself. It was a bit grubby, but mostly disappointingly clean. The engine inlet ports didn’t look too bad so I left them alone.

The exhaust gas pressure sensor was replaced. There seemed nothing wrong with the old one.

VIDA showed nothing useful, according to the garage.

Last routine service was performed by Volvo last Summer a couple of months before these problems arose.

Me

I cleaned the inlet manifold (see above)

I swapped over the two identical MAP sensors and replaced one that looked slightly damaged with a new part from Bosch. No difference to the error message or symptoms.

Although already done by Volvo, I did a full vacuum circuit test with a pump and manometer. I swapped the two identical turbo control valves and bought a new one, just because it was relatively cheap and I was getting desperate. No change.

I spent days and days researching online for a possible solution and talking to friends, etc.

Second Garage

Diagnostics including road tests were performed by a very highly-regarded Bosch specialist garage in the local large town. This was done twice. Garage had no idea what the problem was and were not happy to proceed further.

Third Garage

This is another local garage with a good reputation. They’ve got plenty of kit (not VIDA) but are also a proper, old-school outfit who want to see happy customers.

The car was in for a week. I was advised that as everything else seemed fine, the problem was 90% certain to be with the twin turbo unit. This garage does not rebuild turbos and I could not find anyone within 100km of me prepared to perform a turbo repair. I was quoted just over €4600 for a turbo unit from Volvo. I bought a remanufactured, guaranteed unit from the Netherlands for less than half this amount, but not much less. These seem common enough in UK but were not available readily here in France. Importing from UK is difficult.

I have had the car back from the third garage for a few days. It was with them for 5 weeks. New turbo fitted. Hours and hours of work was expended with other garages being consulted and another mechanic borrowed for 3 hours to inspect the car in case anything had been overlooked. I was only billed for 10 hours, but then I was advised to buy a new turbo.

And now

I have not progressed beyond stage one.

The bills paid exceed €5500.

The sole OBD error is the same P2262 which can be cleared but which arises on first accelerating, together with the CEL light.

Please, please can any kind person give me advice, other than to set fire to the car, or whatever? I am practical, not a bad engineer and have a pretty fair idea about modern engines but am at the end of my tether.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - paul 1963

Have you checked that the exhaust isn't blocked? Collapsed silencer would give the sort of symptoms your experiencing.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Thanks for this, and for replying so quickly. I'm pretty sure the last garage would have done this because they did not fail lightly and spent many, many hours on this. Still, I will try to give this a go. I imagine I need to disconnect the outlet of the DPF. Many people complain about engine access but this car really would win prizes. I think the engine needed to be dropped to change the turbo. I changed the started motor last year and that was very difficult indeed.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - elekie&a/c doctor
Sounds to me like there’s an air leak in the boost pressure system. Has the inlet tract been smoke tested ? Possible intercooler split and leaking boost air ?
Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Thanks for the advice. Volvo did a smoke test and the last garage also. They latter is convinced there is no leak.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - Adampr

I suspect you're considerably more competent than me, so please take this as a 'fresh.pair.of eyes' rather than expert advice.

Your symptoms sound exactly like a problem with the turbo. You are trying to work out if you have a mechanical problem or an electronic one. Given the work you've done, I suspect the latter.

If you put it in neutral and rev it, can you hear the turbo spinning up?

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Thanks, Adam. With respect to an electronic fault I think you must be on the right lines. The last garage can only think there is a software fault which is forcing the boost to collapse before it builds fully.

The last garage used a piece of kit that allowed them to measure actual, rather than calculated boost. They said it measured 1.6 bar and which they reckoned was normal. Where this boost goes is anybody's question because the car seems 100% normally aspirated.

I can't hear the turbo spinning. Looking at the wastegate actuator, it seems that unless the car is moving the wastegate is open. I'm not sure whether this is normal or not. It would seem reasonable.

I do know that I should return to Volvo again in order for them to perform another diagnostic and to reload software. The slight problem I have is that after my fourth visit to them I became rather grumpy when they replaced the exhaust pressure pipe and sensor when there was no fault with it.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - galileo

Thanks, Adam. With respect to an electronic fault I think you must be on the right lines. The last garage can only think there is a software fault which is forcing the boost to collapse before it builds fully.

The last garage used a piece of kit that allowed them to measure actual, rather than calculated boost. They said it measured 1.6 bar and which they reckoned was normal. Where this boost goes is anybody's question because the car seems 100% normally aspirated.

I can't hear the turbo spinning. Looking at the wastegate actuator, it seems that unless the car is moving the wastegate is open. I'm not sure whether this is normal or not. It would seem reasonable.

The wastegate should only open to prevent too much boost or overspeed of the turbo, so should normally be closed, this explains why it runs as if normally aspirated.

I worked at a turbo manufacturer for 36 years, drove experimental installations on cars not then produced turbocharged, a turbo increased performance about 50%.

If one garage claimed to measure boost at 1.6 bar, where did they measure it? presumably not at the inlet manifold.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Thank very much for this very useful information. I will re-check what I stated about the actuator position over the weekend. I don't know where the boost was measured.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - Adampr

I don't think your waste gate should be open at idle.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Thanks again for the advice. See my reply to the other contributor above.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - gordonbennet

Has anyone changed the fuel filter(s)?

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Yes. This was shown on the invoice from the Volvo service last year. Thank you for the suggestion. Much appreciated.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - elekie&a/c doctor
Is this a twin turbo engine , and were both replaced?
Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Yes, it's twin turbo. It comes as a heavy, chunky unit. Made by Borgwarner. Both were replaced.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - focussed
The wastgate actuator is vacuum powered, controlled by a solenoid valve driven by the ECU.
it looks like this according to the parts info.

www.euspares.co.uk/parts/pierburg/16165223

From my previous experience with this type of system, it's easy to get the pipes on the valve round the wrong way, particularly if various mechanics have been at the car.

When the engine is running at idle one of the two pipes should show a vacuum from the vacuum supply.
Easy to check if the valve is working by disconnecting the pipe to the turbo, applying 12 volts to the electrical connnecter
and checking that it switches the vacuum on/off.

Worth checking.

Edited by focussed on 22/04/2025 at 11:48

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Thank for this. Very kind. I will re-check the pipes, more for my peace of mind than in expectation of finding a fault. These solenoid control valves are a bit more complicated than they used to be; the ECU supplies a varies signal to them so that they can vary the vacuum, rather than it just being present or not. One of the first things I did was to swap the two turbo control valves over to see if one was faulty. There was no difference. Because they are relatively affordable I bought a new one (like your link) just in case both were broken. No difference, of course.

I now have a spare turbo actuator, MAP sensor, MAF sensor, Exhaust pressure pipe and sensor and a whopping great BorgWarner twin turbo unit whose replacement cost me €2100 from Rotterdam excluding the ridiculous delivery charge.

What I don't have is a car that works.

Thank again. I'll re-check the pipes as you advise.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Vacuum pipe re-check done. Nothing seems amiss.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Also, I was wrong about the wastegate being open at idle. What seems to happen is a quick open-then-close routine when the car is first started. Thanks to Galilieo and others for correcting me.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - focussed
Give this man and his small company a call/email
He can test and repair just about anything including ECU's
He doesn't detail on his website about Volvo product problems, but he may have heard or know about the problem you have.
He even says you can call him out of hours to discuss your problem.
I have never met this man or have any affiliation with him or his business.

www.remmington.info/index.html
www.remmington.info/contact.html
.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Dear Focussed. Thanks very much for the further help with this. I will certainly contact this chap and let you know how I get on. I've had a quick look at the link you sent and there doesn't seem to be much that he doesn't do!

I've made no progress since my original posting, except to say that very occasionally there IS a surge of boost, or power when I clear the error using my cheap OBD device. This is so rare that the car feels like a totally different vehicle for a few moments before power is lost, the gearbox changes down and the revs increase. The "boost" is not experienced every time I clear the error, just occasionally.

I'm now wondering about the possibility of there being a fault with the electronic throttle body, although there are no errors relating to this. It is about the only part that hasn't been replaced.

Thanks again.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - focussed
Throttle body? Diesels don't normally have throttle bodies.
I was also wondering if the fault could be in the throttle position sender either at the pedal or wherever it's fitted on this car.
If you have a manual and can get the testing procedure and values for the sender etc.

Edited by focussed on 28/04/2025 at 18:57

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews
Yes, there is most certainly a throttle body which is connected with a six-wire connector. When I cleaned the inlet manifold I unbolted it but seem to remember that it would have been impossible otherwise to remove, i.e. if the manifold was in situ. Yes the car is automatic. I don't think the XC90 has been available as a manual for yonks.
Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

I'll certainly look at the accelerator pedal, so thanks for this, as with your other help.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - elekie&a/c doctor
Throttle body on a diesel engine doesn’t do very much to help performance. It’s there to regulate air flow to aid egr control . It’s also an anti shudder device . The flap closes when engine is switched off to prevent run on . I’m still of the opinion that there’s an air leak in the induction system. The fault code has a detected a low boost condition. Also excess fuel consumption because the ecu is trying to compensate for unmetered air by adding more fuel . Just a thought.
Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Thanks for this. From the outset everything pointed to such a leak. The car has now had smoke tests at three separate garages, including Volvo and with nothing to show for this. I'm sure you'll understand my frustration. Is there anything you can suggest that I do?

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - bathtub tom

Thanks for this. From the outset everything pointed to such a leak. The car has now had smoke tests at three separate garages, including Volvo and with nothing to show for this. I'm sure you'll understand my frustration. Is there anything you can suggest that I do?

How would a smoke test be useful on an induction system, unless there's a camera inside the inlet manifold?

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - elekie&a/c doctor
A smoke machine produces smoke / vapour under pressure and introduced into the air inlet tract . Any air leaks will be identified by smoke escaping from any pipes, hoses or joints .
Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - bathtub tom
A smoke machine produces smoke / vapour under pressure and introduced into the air inlet tract . Any air leaks will be identified by smoke escaping from any pipes, hoses or joints .

Thanks for that explanation.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

I should also have said that I'm grateful for your explanation of a diesel engine's throttle purposes. I'd assumed it played a more major part in the engine's performance. Very useful, thanks.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Specifically this is for " elekie&a/c doctor"

While I understand what you say about the throttle body in a diesel engine, surely if there was a fault with it, such as it being kept closed or nearly closed because of damage to the motors or gears, this would affect performance? This could possibly starve the inlet of air as I understand it. I certainly claim no expertise in this matter, but admit my ignorance. When I removed the inlet manifold for cleaning (see my original, long post) I could see that the throttle body was a chunky piece of kit with a valve in it with a diameter of about 10cm. The throttle body's mechanism is closed with rivets rather than bolts. I would expect any malfunction of this unit to throw specific errors but I imagine these could be masked by malfunctions. I'm reluctant to remove the throttle body because a) it's a real bore and involves removing the car's intake manifold and b) your suggestion is that it is most unlikely to be the cause of the fault.

Readers of this thread will understand that my head is frequently under the bonnet of the car while I wonder what on earth is the cause of this fault. It's not a minor problem; the car is pretty much undriveable and when I recently had to use an autoroute for a medical appointment, on an uphill section I crawled along at about 70kmh with the hazard lights on.

I would very gladly pay anyone who can resolve this problem many hundreds of euros! Note how much it has already cost me and to no avail.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - elekie&a/c doctor
The throttle body flap is spring loaded open . The electronics adjust or close it . If it was stuck shut , the engine would not start . Perhaps try disconnecting it to see how that affects performance . Not sure what it does on these , but on most vag models , it makes no difference to engine power .
Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - elekie&a/c doctor
An associate runs a diagnostic workshop in the Netherlands. How far are you from Amsterdam? ( just south of)
Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

I'm in SW France. I ordered the replacement turbo from Rotterdam because I was let down by the only stockist of this remanufactured part in France. In fact, my suspicion is that the French company only work on remanufacturing rarer turbos once an order is received. The Rotterdam company were very helpful. It's just a b***** that in the event there was nothing wrong with the original turbo.

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

I disconnected the throttle body and started the car. ODB showed a P0122 throttle position fault as expected but there was no check engine light. The usual P2262 "Turbocharger boost pressure not detected" had been cleared.

As usual, for the first 200 metres or so on the flat, the car drove as it should. Then, again as usual, power was noticeably lost and the car wanted to rev but had little or no torque. Of course, the P2262 error was again shown on OBD.

Thanks for doubting my theory about the throttle body. You were right.

A reminder that three smoke tests at three different garages have failed to show any leaks.

Volvo won't see the car for five weeks, not that they have done anything at all except smoke test change working parts, and say "Yes, Sir. You're correct. Your car doesn't work".

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - gordonbennet

I too am unsure how the throttle flap would operate on your car.

On my Toyota, when fully open the engine can intake clean air directly from the turbo/intercooler, at light throttle openings the EGR valve is opened allowing exhaust gases (containing carbon and combustion crud) into the intake, that's why the egr housing and intake manfolds get caked in carbon/oil crud.

One can surmise if the flap was sticking partly open or otherwise not operating properly why power would be down and excess fuel used as the car would be running on reduced aiurflow and unburned gases continually however jamming it in the open position would no doubt cause an engine management light, but it might be an interesting experiment to see if full power is once again on tap with the valve open, though once the warning light appears its likely fuel flow is cut to limit power....removing the flap itself but leaving the spindle connected as it should would allow the spindle to turn as if the flap was still in place, that should then not trigger a warning, but as you've noted the flap is probably secured by screws that can't be undone.

Without reading back, you have cleaned out the egr and inlet manifold?, are there swirl flaps on the inlet maifold where it enters the cyl head? are these clear and opening/closing...its a regular job on some BMW Diesels to remove these flaps, which have been know to come loose and get ingested by the engine causing massive damage, owners generally notice several improvements once these flaps are binned.

Edited by gordonbennet on 30/04/2025 at 16:57

Volvo XC90 (II) D5 256 2016 - Volvo XC90 Diesel Significant Lack of Power & MPG - A Andrews

Thanks Gordon Bennet. I did remove the inlet manifold myself and gave it a clean. This process is hidden in the rather long original description above. I did this because Volvo wanted a ridiculous amount of cash to do it and said that it was the "next step" in the process after they'd replaced the EGR valve and EGR cooler body. The inlet manifold wasn't as dirty as I's wanted it to be, if you get my drift. The swirl flaps were fine. The throttle body and butterfly valve were very clean indeed.