Stupid Car Design - Volvo S40 Turbocharger replacement.

[Petrolhead_Rich]

Due to recent issues with my car I'm putting my 2004 Volvo S40 back on the road (taken off because it needed a new turbo.

Looking in Haynes today:

[quote=Haynes]
Tubocharger - Removal and Refitting (4 spanners)
Remove the exhaust manifold (see Section 16)

Section 16 - Manifolds removal and refitting

1 [..]
2 [..]
3 Drain the cooling system
4 Remove the Battery & Battery Tray (see Chapter 5a)
5 Disconnect the gear change cables from the transmission levers
6 [..]
7 Remove the Driveshafts (Chapter 8)
8 Suspend right side of engine
9 Remove lower Torque rod from engine
10 remove steering rack bolts and suspend
11 place jack under subframe and remove subframe
12-17 [...]
18 Remove Catalytic Converter
19 Remove wires/pipes to turbocharger

[back to the 4 spanner job of removing the Turbo]

Come on, seriously did nobody at ford think hmm, the turbo might fail and it's nigh on bloody impossible to change it, oh well never mind!

At least it explains why Volvo quoted over £1200 to change the Turbo

Is it just me that thinks that is a little excessive to change a Turbo which is likley to fail???

Not looking forward to this job, glad I have a week off....

[Petrolhead_Rich]

doogz said:

What do Ford have to do with it? It's a Volvo.

It's a Ford Focus with big bumpers and a slightly better interior....

[useyourdellusion]

Good luck with removing the exhaust manifold for a start!

[TXWRX]

How many turbo's have you been through? its unlikely that it would fail often enough to warrant the type of packaging needed to make it 'easy' to change, that will have all been looked at when they did the cars FMEA

[boredofmyoldname]

After you got to item 4 I got lost, good luck.

[The Wookie]

If the turbo has been designed to last more than 3 years then I'd say they got it just about spot on

ETA - If that's a 4 spanner job, what the feck is a five spanner like!

Edited by The Wookie on Monday 24th January 14:56

[Petrolhead_Rich]

doogz said:

Petrolhead_Rich said:

doogz said:

What do Ford have to do with it? It's a Volvo.

It's a Ford Focus with big bumpers and a slightly better interior....

With a Volvo engine fitted. That Volvo designed.


Anyway, sounds like a bd of a job, good luck with it.

Ford Focus TDCI engine, that Ford Designed, against a ford bulkhead.

Either way it's a stty design, and fair enough that your only likley to change the turbo once but the Cat, Oil Pipes, EGR valve etc is all stuck down the back of the engine with feck all room.

but seriously, SUBFRAME out to change a turbo???

I will take some pictures as I go along, see you in a few days!!!

[NHK244V]

All modern cars are packaged like that, how about a spinter where you need to smash the glow plugs out and replace with new ones just to change the rocker cover gasket ? or drop the steering rack and a driveshaft to change the alternator i could go on and on and on and on and errr well you get the point

[TankRizzo]

I had a 306 Dturbo that was a bit like that, you had to drop the engine off one of its mounts and jack it forward to even see the turbo which was down the back of the engine somewhere.

And then the manifold bolts would snap off when you tried to remove it.

[EDLT]

TankRizzo said:

I had a 306 Dturbo that was a bit like that, you had to drop the engine off one of its mounts and jack it forward to even see the turbo which was down the back of the engine somewhere.

And then the manifold bolts would snap off when you tried to remove it.

Can't you access it from underneath? I know you can get at the manifold bolts that way on the NA diesel engines.

[TankRizzo]

EDLT said:

Can't you access it from underneath? I know you can get at the manifold bolts that way on the NA diesel engines.

No, there was bugger-all access from underneath, especially on mine which had the aircon pipes obstructing things too. The engine mount procedure was actually the Haynes method, I almost crapped a wardrobe when I looked at it - all the turbo swaps I've ever seen first-hand were on Cossies which were nicely accessible from the top.

[TheEnd]

The first step in changing the clutch on my E36 was "remove the wiper arms"

I knew then my knuckles were in for a bad ride.

[Acheron]

Isnt it the GSi Vectra (the 3.2) that needs engine out for the cambelt to be changed? (Either that, or the fiat Coupe, and im not sure why i have confused them both).

[Mr Dave]

NHK244V said:

All modern cars are packaged like that,

Plenty of old cars are stupidly designed and hard to do certain things on, its not just new cars!

A Jaguar V12 in an old XJS being the bane of my life so far, few tricky packaging jobs on old Porsches as well!

[.:ian:.]

Had to replace the brake servo on my GTV recently, LHD instructions looked easy, undo linkage, few bolts, job done. RHD varient.. Starting from the passenger side remove dash... :-o

To get the servo out required dash, steering column and pedal box to be removed.

To unbolt the slave cylinder required the inlet plenum to be removed (workshop manual suggested removing engine tiebar and levering it forward.. fairytales.. ) which required the exhaust front section to be removed and 600mm of socket extension bits to reach the bolts.

[vrooom]

THey are designed like that to chargerape you in dealership.

[GPR13]

Petrolhead_Rich said:

doogz said:

Petrolhead_Rich said:

doogz said:

What do Ford have to do with it? It's a Volvo.

It's a Ford Focus with big bumpers and a slightly better interior....

With a Volvo engine fitted. That Volvo designed.


Anyway, sounds like a bd of a job, good luck with it.

Ford Focus TDCI engine, that Ford Designed, against a ford bulkhead.

Either way it's a stty design, and fair enough that your only likley to change the turbo once but the Cat, Oil Pipes, EGR valve etc is all stuck down the back of the engine with feck all room.

but seriously, SUBFRAME out to change a turbo???

I will take some pictures as I go along, see you in a few days!!!

Not sure about the 2.0l TDCI but the 1.8 is a PSA engine not a Ford engine

[Compo_Simmonite]

On the Volvo 440 from year ago you have to drop the subframe to remove the gearbox. Just about possible to move it enough to change the clutch with it in situ.
On 1990 MKIII Passat 2.0 GL auto you have to drop subframe to remove steering rack.
With my Smart you have to drop subframe to do a proper service. You can even get longer bolts from Merc to allow it to drop 6" or so !

What I'm trying to say is it's nothing new and not a massive problem either as long as you accept it's part of the proceedure.

I'm sure someone comming from a sidevalve to a OHV would have moaned about extra work to change head gasket just like someone changing from OHV to OHC might moan about cam belt changing. All "part and parcel" of improvements (not always for the DIY'er's better).

Paul H

Edited by Compo_Simmonite on Tuesday 25th January 08:57

[white90]

Petrolhead_Rich said:

Due to recent issues with my car I'm putting my 2004 Volvo S40 back on the road (taken off because it needed a new turbo.

Looking in Haynes today:

Haynes said:

Tubocharger - Removal and Refitting (4 spanners)
Remove the exhaust manifold (see Section 16)

Section 16 - Manifolds removal and refitting

1 [..]
2 [..]
3 Drain the cooling system
4 Remove the Battery & Battery Tray (see Chapter 5a)
5 Disconnect the gear change cables from the transmission levers
6 [..]
7 Remove the Driveshafts (Chapter 8)
8 Suspend right side of engine
9 Remove lower Torque rod from engine
10 remove steering rack bolts and suspend
11 place jack under subframe and remove subframe
12-17 [...]
18 Remove Catalytic Converter
19 Remove wires/pipes to turbocharger

[back to the 4 spanner job of removing the Turbo]

Come on, seriously did nobody at ford think hmm, the turbo might fail and it's nigh on bloody impossible to change it, oh well never mind!

At least it explains why Volvo quoted over £1200 to change the Turbo

Is it just me that thinks that is a little excessive to change a Turbo which is likley to fail???

Not looking forward to this job, glad I have a week off....

Rich
I have just looked at Vadis and for the >2004 S40 I can email you the Vadis pages if you want them.

Edited by white90 on Tuesday 25th January 10:10

[Petrolhead_Rich]

white90 said:

Petrolhead_Rich said:

Due to recent issues with my car I'm putting my 2004 Volvo S40 back on the road (taken off because it needed a new turbo.

Looking in Haynes today:

Haynes said:

Tubocharger - Removal and Refitting (4 spanners)
Remove the exhaust manifold (see Section 16)

Section 16 - Manifolds removal and refitting

1 [..]
2 [..]
3 Drain the cooling system
4 Remove the Battery & Battery Tray (see Chapter 5a)
5 Disconnect the gear change cables from the transmission levers
6 [..]
7 Remove the Driveshafts (Chapter 8)
8 Suspend right side of engine
9 Remove lower Torque rod from engine
10 remove steering rack bolts and suspend
11 place jack under subframe and remove subframe
12-17 [...]
18 Remove Catalytic Converter
19 Remove wires/pipes to turbocharger

[back to the 4 spanner job of removing the Turbo]

Come on, seriously did nobody at ford think hmm, the turbo might fail and it's nigh on bloody impossible to change it, oh well never mind!

At least it explains why Volvo quoted over £1200 to change the Turbo

Is it just me that thinks that is a little excessive to change a Turbo which is likley to fail???

Not looking forward to this job, glad I have a week off....

Rich
I have just looked at Vadis and for the >2004 S40 I can email you the Vadis pages if you want them.

Edited by white90 on Tuesday 25th January 10:10

It's a 2004> sadly! but many thanks, do you have access to the new VIDA system? I'm planning on retro-fitting cruise control soon but apparently it needs plugging in to tell it its there!!!

Thanks Again