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nik77

S60 failed mods

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Hi

My 2006 S60-T5 was involved in bad accident. The engine fortunately still okay. I bought a 2007 S60-2.0T then

I asked my mechanic to transplant the T5 2.4 engine into newer 2007 S60. My fault, i just leave the car for 1 month without updating transplant jobs. I just blindly trust the mechanic 

He transplant the T5 2.4 engine, but sadly he use S60 2.0T wiring, ecu, tcu , fuel rail and 2.0T automatic transmission that don't have semi auto shift and only have STC. (The T5 2.4 use DSTC). Injectors is white from T5 2.4 and also retain K24 turbocharger 

Part of mods...He added 3" turbo downpipe and high flow 2.5" cat, 2.5" cat back exhaust system, front mount intercooler, engine oil cooler and Deatschwerk 255 lph fuel pump. Then he sent the car for stage 2 tuning by using 2.0T ecu and tcu .

The power is good. But unfortunately and sadly, the transplant job suffering permanent hard start and jumpy idling. I need to buy Ultragauge OBD meter to reset error code every time to start the car. 

The mechanic said the hard start and erratic idling maybe because of using 2.0T fuel rail that has no Fuel Pressure Sensor and due to rich fuel because using 255 lph fuel pump.

I love this car. Do u guys have advise to eliminate hard start and erratic idling?

Many thanks 

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I think the issue is with the tune. If you're using the 2.4 T5 injectors/rail in the 2.0 car, it's not going to run very well because the ECU is expecting smaller injectors. You can either swap back the 2.0 rail/injectors or get a tune for the correct injectors (you'll want to do the latter for the best performance).

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8 hours ago, bmdubya1198 said:

I think the issue is with the tune. If you're using the 2.4 T5 injectors/rail in the 2.0 car, it's not going to run very well because the ECU is expecting smaller injectors. You can either swap back the 2.0 rail/injectors or get a tune for the correct injectors (you'll want to do the latter for the best performance).

Thanks. Currently the T5 2.4 use factory spec injectors  , which is white, i think the white injectors is 395 cc. As for fuel rail, the car is using 2.0T fuel rail. As for 255 lph fuel pump, i don't think it causing rich fuel mixture. The remap/tune should get 300bhp/400nm according to tuner. Need to do dyno to get exact figures. With the tuned, i can feel the car is much powerful compared to original spec 260bhp/350nm. The narrow band lambda AFR read normal 

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I don't think the fuel pump is the issue either, what I'm saying is that the ECU is anticipating the 2.0 injectors, but the engine is running 2.4 injectors. That will certainly cause rough idle issues.

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So you currently have a tune, correct? The tune is for the correct engine/turbo/injectors that are installed in the car?

If so, check over the basics... how old is your MAF? Have you connected VIDA to check for codes and check MAF, fuel trim, and other values?

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Yes sir. Remap/tune stage 2. Yes...the tune is to harmonize the engine, turbo, injectors , boost limit and air fuel ratio . The tuner inspect the K24 turbocharger(still okay) and he offer to upgrade using green injectors to up some more power.

Other than morning hard start and erratic idling, the car running fine

Unfortunately today, the car has new problem. While in bumper to bumper traffic jam, the boost meter go up and down...then engine die. I restart back , engine come to life with 1 crank and the car move again, then it die again. After talking with several S60 owners and the mechanic , he decided to change all small hoses at intake pipe, tcv hose, all vacuum hoses, check intercooler plastic pipe over the engine,  clean the ETM and pcv tank.

If all these don't cure the sudden engine die...mechanic will proceed to new fuel pump or maybe change new ETM . It use Bosch ETM 

Hopefully fuel pump and ETM still good. 

Thanks 

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The Bosch throttles rarely (if ever) fail, while the Magneti Marellis are always dying. Hopefully it's something simple like a vacuum leak, it's =possible that it could have been the problem. The plastic pipe that attaches to the ETM could also have been loose (although I would assume your mechanic would have noticed that right away) and at least came close to blowing off, which would explain the sudden worsening of symptoms (long shot, but anything's possible).

I think it's very possible that you have a vacuum leak.

Good luck!

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On 8/23/2019 at 9:08 AM, bmdubya1198 said:

The Bosch throttles rarely (if ever) fail, while the Magneti Marellis are always dying. Hopefully it's something simple like a vacuum leak, it's =possible that it could have been the problem. The plastic pipe that attaches to the ETM could also have been loose (although I would assume your mechanic would have noticed that right away) and at least came close to blowing off, which would explain the sudden worsening of symptoms (long shot, but anything's possible).

I think it's very possible that you have a vacuum leak.

Good luck!

Thank you

The culprit is the plastic intake hose...the one from MAF to turbocharger. The end side which connects to turbocharger is crack. I asked the mechanic to clean the Bosch ETM and pcv breather system. The Pcv tank itself is okay, just need to buy complete piping for pcv breather system. Also will change hoses to TCV and any other small hoses

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12 hours ago, nik77 said:

Thank you

The culprit is the plastic intake hose...the one from MAF to turbocharger. The end side which connects to turbocharger is crack. I asked the mechanic to clean the Bosch ETM and pcv breather system. The Pcv tank itself is okay, just need to buy complete piping for pcv breather system. Also will change hoses to TCV and any other small hoses

Yup, that could definitely cause some issues! Hopefully that's all it takes to get you running smoothly!

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2 hours ago, bmdubya1198 said:

Yup, that could definitely cause some issues! Hopefully that's all it takes to get you running smoothly!

Thanks 

Tomorrow will pick up the car. Hope all are okay. 

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On 8/25/2019 at 10:05 PM, bmdubya1198 said:

Yup, that could definitely cause some issues! Hopefully that's all it takes to get you running smoothly!

Hi

Finally my S60 runs fine. 

I was ignorance before. Such simple jobs i.e cleaning ETM, pcv breather system, cleaning intake manifold, all new small hoses, and plastic intake pipe to turbocharger....

No more erratic idling and jerking. Turbocharger spools smoothly . 

Do you know sir the original S60-T5 2.4 fuel pump pressure flow? Currently using Deatschwerk 255 lp/h. Since my S60-T5 mods is using 2.0T fuel rail with no fuel pressure sensor (fps) , can i use adjustable fuel pressure regulator to smooth out fuel pressure?

 

Thanks 

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I don't believe these cars have an adjustable fuel pressure regulator. That's something you would need to add.

That said, the 255 LPH pump should be just fine in your S60. People use similar pumps all the time in P80s (DW200, DW300), and Deatschwerks makes some good fuel pumps.

Glad you got the idle issues sorted out!

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