Workshop Manuals Factory service & repair Volvo

Volvo common faults and how to fix them

Faults that are well known on Volvo models we hold manuals for: what the owner notices, what causes it, and the pages in our manuals that cover the repair.

Volvo engine system service required: electronic throttle module (ETM) faults (1999–2002)

Symptoms

An "Engine system service required" or "service urgent" message, the engine light, and the car drops into limp mode with little power. Some cars stall, surge or hesitate at low speed or when pulling into traffic. It affects the 1999–2002 C70, S70, S60, V70, V70 XC and S80 with the five- and six-cylinder petrol engines.

Cause

The electronic throttle module (ETM) opens the throttle by motor, with no cable. An NHTSA investigation (EA05021) traced faults to throttle position sensor problems, a dirty throttle housing and software calibration, and linked them to stalling and limp mode. Volvo recalled about 360,000 cars in 2006. Volvo's bulletins clean the crankcase ventilation system and the throttle housing together, as oily deposits from the ventilation system foul the housing.

Fix

Read the fault codes and follow Volvo's fault tracing before replacing the module; bulletin TNN 25-149-E says replacement must always be preceded by it. Check whether the recall software has been loaded. Clean the throttle housing and the Volvo PCV valve system as the cleaning procedure describes, and renew the Volvo flame trap and its seals if they are blocked. If the module itself has failed, replace it and run the adaptation with a diagnostic tool.

Repair instructions on this site

Sources: Volvo bulletins TNN 25-149-C, D and E; NHTSA engineering analysis EA05021; Fox News / AP — Volvo recalls 360,000 cars (2006).

Volvo AW55 transmission problems: shift solenoid S5 codes 010A, 010B and 010C (2004–2005)

Symptoms

A gearbox warning or the engine light comes on, shifting may be affected, and the gearbox control module stores code 010A, 010B or 010C for shift solenoid S5 (signal low, high or missing). It affects 2004–2005 S40, V50, S60, V70, XC70, S80 and XC90 models with the five-speed AW55 automatic.

Cause

Volvo bulletin TNN 43-49 says the likely cause of these codes on a 2004 or 2005 car is a broken wiring terminal at the S5 solenoid inside the gearbox, not a failed solenoid or gearbox. The bulletin names the AW55 transmission in all these models.

Fix

Follow Volvo's fault tracing for the codes, as the bulletin directs, and check the S5 solenoid terminal and wiring before condemning the solenoid or the valve body. The Volvo transmission problems bulletin covers repairing or replacing the gearbox wiring harness. Clear the codes and reset the gearbox adaptation after the repair.

Repair instructions on this site

Sources: Volvo bulletin TNN 43-49 (April 2006).

Volvo rough idle and misfire: worn intake valves on 2004 models

Symptoms

A rough idle, rough running, a lack of power and the engine light on with misfire codes. Compression is low on one or more cylinders. It appears in our 2004 S40, S60, S80, V70, V70 R and XC90 manuals.

Cause

Volvo bulletin TNN 21-21 traces the complaint to worn intake valve faces on some 2004 model-year engines. A worn valve face no longer seals, so the cylinder loses compression and misfires.

Fix

Read the fault codes, then do a compression test and a leak-down test with the engine cold. Check the valve clearances on any cylinder with low compression. If that does not explain it, remove the cylinder head and inspect the valve faces. The Volvo rough idle bulletin says that if any face is worn, all the intake valves are replaced, even those that look fine, using only part number 30637059.

Repair instructions on this site

Sources: Volvo bulletin TNN 21-21 (August 2005).

Repair instructions for every Volvo model: Volvo workshop manuals