Volvo S40 Manifold replacement - approx cost?

olewy

Background info;
2005 Volvo S40 1.8 S petrol.
Emissions light on dash is regularly on & power is severely restricted in all gears to the point of being almost unsafe to drive (e.g. pulling away, accelerating etc).

I had a local indy mechanic open up the engine & he cleared out some gunge which was trapped around the swirl flaps. This helped (noticeable increase in power after the cleaning, almost back to normal) but the issue soon returned & is now as bad as ever.

The mechanic thinks the manifold should be replaced. Any thoughts on whether this sounds logical/right?
One fairly large motor factor said they don't stock the manifolds as the part is too big in size & said to contact Volvo to get it.

Volvo dealers are very pricey from experience so rather than get fleeced by a Volvo dealer where would be the next best place to get a manifold for this model if motor factors don't sell them new? I assume refurbished is my only route? If so I guess these would be from a scrap yard or something? Any ideas on average what a refurbished manifold might cost?

Any help appreciated. Tks.

Anan1

olewy wrote: »

The mechanic thinks the manifold should be replaced. Any thoughts on whether this sounds logical/right?

What did he say is wrong with it that it needs to be replaced?

olewy

Anan1 wrote: »

What did he say is wrong with it that it needs to be replaced?

He spoke to a family member so I need to confirm directly with the mechanic to know for sure what he said. He did say though that he contacted Volvo who confirmed his belief that the fix is a manifold replacement.

Hellrazer

Get a second opinion. In 8 years with Volvo I never ever heard of a problem with the manifold in that model.

That engine is fairly robust in that it gives very little problems.

bazz26

If it is confirmed as the manifold, would a manifold from a Mondeo fit it given that the 1.8 litre engine in the S40 is basically the same one found in the Mondeo? Or is that too simplistic?

Hellrazer

bazz26 wrote: »

If it is confirmed as the manifold, would a manifold from a Mondeo fit it given that the 1.8 litre engine in the S40 is basically the same one found in the Mondeo? Or is that too simplistic?

Doubt it.

Id say Focus 1.8 flexi would be a better fit more likely but there was feck all of them sold.

olewy

Hellrazer wrote: »

Get a second opinion. In 8 years with Volvo I never ever heard of a problem with the manifold in that model.

That engine is fairly robust in that it gives very little problems.

Thanks. The mechanic has sourced a refurbished manifold & can replace it for a very good price. He just needs to check that its the correct/compatible part. If it is I'll probably go ahead with that to see if it fixes it.

I would get a 2nd opinion if it wasn't for the fact that I think Volvo themselves confirmed that a manifold replacement would be the next step (tbc).

Hellrazer

olewy wrote: »

I would get a 2nd opinion if it wasn't for the fact that I think Volvo themselves confirmed that a manifold replacement would be the next step (tbc).

Who confirmed it in Volvo?
How would they know unless the car was with them?

olewy

Hellrazer wrote: »

Who confirmed it in Volvo?
How would they know unless the car was with them?

Unknown, as I said; all 2nd hand info.

gibbon75

Hellrazer wrote: »

Get a second opinion. In 8 years with Volvo I never ever heard of a problem with the manifold in that model.

That engine is fairly robust in that it gives very little problems.

I'm with Hellrazer on this one:we've never seen a manifold problem with these engines.
On the other hand we sold plenty of the twin solenoid that regulates the swirl packs though...

olewy

gibbon75 wrote: »

I'm with Hellrazer on this one:we've never seen a manifold problem with these engines.
On the other hand we sold plenty of the twin solenoid that regulates the swirl packs though...

Twin solenoid....thanks for the tip. That might save me some time & money. I'll look into it.

scorn

That's odd - I have the same year and model (S40) and the orange engine light has been on for ages. The mechanic we use said that the cat was gone, and on investigation as to the cause of cat failure said that the engine was blowing burnt oil... So the suggestion was a replacement engine or rebuild!


I asked a 'Volvo expert' on a website who suggested to check the PCV valve first as this could also cause burnt oil to reach the cat.

From the guys who work in/with Volvo here - does this sound like the same issue as the op?

olewy

scorn wrote: »

That's odd - I have the same year and model (S40) and the orange engine light has been on for ages. The mechanic we use said that the cat was gone, and on investigation as to the cause of cat failure said that the engine was blowing burnt oil... So the suggestion was a replacement engine or rebuild!


I asked a 'Volvo expert' on a website who suggested to check the PCV valve first as this could also cause burnt oil to reach the cat.

From the guys who work in/with Volvo here - does this sound like the same issue as the op?

Thanks scorn. Some quick questions;
Did you also experience reduced power in all gears as a symptom?
Did you have the PCV valve and/or Cat replaced?
If so did either of these fix the issue for you or are you still driving with the emissions light on?

scorn

Hi olewy

We didn't experience reduced power (well, that I'm aware of - the wife drives the car mostly, I'm on a motorbike) but there have been a few times where there has been a message stating 'Reduced Engine Performance'. Have you seen that message yourself? Haven't seen it lately though.

I haven't had the cat replaced - quote for €525 for aftermarket part (though been told it's as good or better than the original) as I need to resolve the issue as to why it went in the first place. Don't want it happening again after spending the money.

Haven't had a chance to get the PCV looked at. The mechanics said they'd look and (if needed) replace it for around €100-150. They're fairly convinced it's the engine that's blown though - they say they've seen it before in Mondeos... So it's a gamble for us.

Still driving with the light on!

Pkiernan

olewy wrote: »

Thanks scorn. Some quick questions;
Did you also experience reduced power in all gears as a symptom?
Did you have the PCV valve and/or Cat replaced?
If so did either of these fix the issue for you or are you still driving with the emissions light on?

What fault code is being given?

R.O.R

We had reduced performance and engine light intermittently on, on the wife's old V50 1.8. Would occasionally throw up the "reduced engine performance" message as well.

Eventually wouldn't start and it was the alternator that had given up the ghost - common enough issue on the S40/V50 1.8.

Might just be a symptom that the alternator is on the way out?

scorn

Pkiernan wrote: »

What fault code is being given?

In my case the reason the light is on is due to emissions (makes sense I think, seeing as the cat has blown).

(I don't know the actual code though - oh, and I wouldn't know the code for the 'reduced engine performance' error)

olewy

Pkiernan wrote: »

What fault code is being given?

I don't know, I must ask my indy mechanic if he even has the diagnostic machine to check the code. I assume he has already, I hope so, otherwise he could be way off.

olewy

R.O.R wrote: »

We had reduced performance and engine light intermittently on, on the wife's old V50 1.8. Would occasionally throw up the "reduced engine performance" message as well.

Eventually wouldn't start and it was the alternator that had given up the ghost - common enough issue on the S40/V50 1.8.

Might just be a symptom that the alternator is on the way out?

Thanks I'll run that by him too. The car has always had an intermittent issue of sometimes failing to start/turn-off from cold but after a few attempts always starts. Perhaps that could be related to/point to the alternator too.

R.O.R

olewy wrote: »

Thanks I'll run that by him too. The car has always had an intermittent issue of sometimes failing to start/turn-off from cold but after a few attempts always starts. Perhaps that could be related to/point to the alternator too.

We also had hard start issues before the Alternator went up the swanny.

It's beginning to sound more and more like it could be the same thing. Not sure if there is any way to diagnose it definately as an alternator issue though. Ours just eventually sat down and had to be towed.

It's not cheap either, around €600 - €700 from an indy mechanic I'd say.

olewy

R.O.R wrote: »

We also had hard start issues before the Alternator went up the swanny.

It's beginning to sound more and more like it could be the same thing. Not sure if there is any way to diagnose it definately as an alternator issue though. Ours just eventually sat down and had to be towed.

It's not cheap either, around €600 - €700 from an indy mechanic I'd say.

Ouch! I wonder would that approximate price be for a Volvo 'official' alternator or a Ford branded part, given the usual big cost difference between most Volvo/Ford parts that are compatible with the S40.

olewy

gibbon75 wrote: »

I'm with Hellrazer on this one:we've never seen a manifold problem with these engines.
On the other hand we sold plenty of the twin solenoid that regulates the swirl packs though...

Re twin solenoid; seems like it's a common fix for this issue alright; http://www.volvoforums.org.uk/archive/index.php/t-88154.html

So probably twin solenoid or alternator at this point.

R.O.R

olewy wrote: »

Ouch! I wonder would that approximate price be for a Volvo 'official' alternator or a Ford branded part, given the usual big cost difference between most Volvo/Ford parts that are compatible with the S40.

My price was based on using the cheaper Ford part. Volvo (via a dealer) were quoting around €1,200 I think.

gibbon75

R.O.R wrote: »

My price was based on using the cheaper Ford part. Volvo (via a dealer) were quoting around €1,200 I think.

AFAIK Ford raised the price of the alternator,so the Volvo one is the cheaper option now.

Hellrazer

gibbon75 wrote: »

AFAIK Ford raised the price of the alternator,so the Volvo one is the cheaper option now.

Cheapest option is to replace the 10 cent resisitor that's blowing in them

The polish lad that's mentioned here a few times can repair these for a fraction of the main dealer price.

gibbon75

Hellrazer wrote: »

Cheapest option is to replace the 10 cent resisitor that's blowing in them

The polish lad that's mentioned here a few times can repair these for a fraction of the main dealer price.

A half decent auto electrician can repair these too

R.O.R

Hellrazer wrote: »

Cheapest option is to replace the 10 cent resisitor that's blowing in them

The polish lad that's mentioned here a few times can repair these for a fraction of the main dealer price.

He didn't do a brilliant job on the first one At least it was cheap, but only held out for about 3 months, so had it done with a new unit rather than a recon.

Hellrazer

R.O.R wrote: »

He didn't do a brilliant job on the first one At least it was cheap, but only held out for about 3 months, so had it done with a new unit rather than a recon.

Must have a word with him about that. Thought he had these down to a permanent fix.

olewy

Hellrazer wrote: »

Must have a word with him about that. Thought he had these down to a permanent fix.

Hi Hellrazer, can you PM me his contact details please? I may need to use his services depending on how things progress.

Status;
I can't get in touch with my indy mechanic (not answering his phone) to confirm the following;

1. What fault code is coming up. Or if this was checked.
2. Run the following potential root causes/fixes by him (in this order) instead of replacing the manifold;

i) Check the Throttle Swirl Control Solenoid (aka twin solenoid) which control the swirl flaps & regularly go according to 2 Volvo mechanics on this thread plus other Volvo S40 owners on other forums.

ii) Check the Alternator (i.e. replace 10 cents alternator resistor, recondition alternator or replace alternator)

iii) Check Cat health & if its gone check the PCV valve

Can anybody here recommend a reliable & reasonably priced Indy mechanic on the south side of Dublin or preferably North Wicklow where I could get the above items checked?

olewy

R.O.R wrote: »

He didn't do a brilliant job on the first one At least it was cheap, but only held out for about 3 months, so had it done with a new unit rather than a recon.

Hi R.O.R. can you PM me his contact details please?

_Conrad_

Hellrazer wrote: »

Must have a word with him about that. Thought he had these down to a permanent fix.

Something else could be going on there too, or a combination of problems.

olewy

olewy wrote: »

Hi Hellrazer, can you PM me his contact details please? I may need to use his services depending on how things progress.

Status;
I can't get in touch with my indy mechanic (not answering his phone) to confirm the following;

1. What fault code is coming up. Or if this was checked.
2. Run the following potential root causes/fixes by him (in this order) instead of replacing the manifold;

i) Check the Throttle Swirl Control Solenoid (aka twin solenoid) which control the swirl flaps & regularly go according to 2 Volvo mechanics on this thread plus other Volvo S40 owners on other forums.

ii) Check the Alternator (i.e. replace 10 cents alternator resistor, recondition alternator or replace alternator)

iii) Check Cat health & if its gone check the PCV valve

Can anybody here recommend a reliable & reasonably priced Indy mechanic on the south side of Dublin or preferably North Wicklow where I could get the above items checked?

Update; fault code is P2008 which apparently indicated the Throttle Swirl Control Solenoid (exact details that came with the code I don't have). Motor factors weren't able to pull it up on their system based on the part description alone so I need a part number. Does anyone have a part number for a Throttle Swirl Control Solenoid? Thanks.

gibbon75

31375551

That is the "twin" solenoid we have mentioned before.