[Swede40]

Hey everyone! I was finishing up an oil change today and while I had to the front end jacked up I noticed a rattling noise. I noticed it is subtle at idle, but when I rev to 1000 to about 1200 RPMs it's very noticeable and then is less noticeable at higher RPMs. It's a 2006 S40 T5 AWD M66

In this video you can hear it. It's especially loud around 18 seconds. You can hear it speeds up at around 18 seconds when I revved to 1100 RPM. Here is the video: New video by Michael Jefferies

Any ideas what to check? I can't quite pinpoint the source of the rattle so I'm not sure where to start checking.

Of note, I recently lost my splash guard. It's funny because I noticed the previous owner had it held up with zip ties and had some missing screws so I actually just bought all new screws and the plastic sockets that hold up the splash guard. I was going to replace them today while it was jacked up, but the splash guard was missing. I'm guessing it's final resting place is at the ski resort near my house where I drove through snow last LOL.

Other recent work that may or may not be related:

• Replaced brakes and rotors few weeks ago
• Replaced clutch and flywheel (full clutch) few weeks ago
• Did engine flush today before oil change, then added Liqui Moly Ceratec to the oil when refilling the oil
• Replaced entire front and rear suspension 3 months ago
• Timing belt and water pump about 6 months ago

Thanks!
Mike

 

[ArkV50]

hey, I don't have much knowledge but it sounded as exhaust manifold protection. Previously I had a Civic and it had exactly same sound. Later I noticed that the reason was the metal protection plate of exhaust manifold. Top 2 bolts were okay but bottom one was making the sound.

 

[volvogod]

Engine off. Hit the cat with a rubber hammer and see if you hear a rattle. Sounds like the cat media melted. While making the noise, push pull pry on the exhaust pipe and see if it changes. The pipe may be touching something, or exhaust pipe mount/hanger could have broken.

 

[avenger09123]

If things aren't rattling at 12,000RPM, it wouldn't be a Volvo...

 

[AM Reed]

Sounds like loose heat shield rattle to me, or a broken exhaust hanger. Also check the cat as @volvogod says

 

[Swede40]

I did some troubleshooting and still need help. I was able to locate the general area of the rattle. It appears to be right above the transfer case. I got a video here and if you watch to the end you can see and hear it. I'm not sure what is up there but that's where the sound is coming from.

Here's the video: New video by Michael Jefferies

I hit the catalytic converter with a mallet and it shakes but it makes a difference sort of noise. I don't think that is it.

I recently had the clutch replaced and I'm wondering if something got loose while that work was done. I also recently lost my splash shield and that may have left the area vulnerable.

Thanks for any help or suggestions!

 

[AM Reed]

You've got a couple heat shields in that area -- did you check those?

 

[thefisch33]

That's your best shield, or at least one of the bolts that's on a spring that keeps the heat shield attached to the block.


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[Swede40]

That's your best shield, or at least one of the bolts that's on a spring that keeps the heat shield attached to the block.

@thefisch33 and @AM Reed this is going to sound dumb but what is the best way to get at those shields and check them? They are crammed back in there above the transfer case and so when I hit it with a long screwdriver it replicates the noise but I'm not sure how to get at it and actually fix it. I'm looking through the Vids software, my Haynes manual, and googling but no luck so far.

While I was under there I found a bolt missing and I'm wondering if the shop forgot a few bolts when they did my clutch a few weeks ago..

For example, this bolt is missing. I'm also trying to track that down.

 

[LittleRedRidingHood]

You can access it from top Remove the intake pipe and you'll have clear access to the bolts holding on the turbo heatshield.

Yes, definitely suggest replacing that turbo hardpipe bolt.

 

[volvogod]

That bolt is #7, 7mmX16mm long, 3 bolts.

 

[Swede40]

Thanks everyone. I haven't been able to pinpoint the source of the sound yet, but I took another video pointed down at the heat shields. I've never actually seen the Volvo heat shields. When I look down I see one that looks pliable and not like metal that would rattle. Am I looking at the right area? Are some or all of the heat shields thin metal that would make that rattling noise?

Here is the video of the rattling looking down into the engine:

0 new items by Michael Jefferies

photos.app.goo.gl

The rattle is happening at exactly 9000 to 9500 RPM. EXACTLY. Not higher, not lower. It happens warm or cold.

It could be unrelated, but I've also been suspicious that it's time to change my exhaust manifold gasket and bolts. I've had a squealing noise during turbo boost at acceleration. I don't have other exhaust manifold gasket symptoms such as the smell, but when I went in there a few months ago one of the exhaust bolts was so loose that I could have unscrewed it with my hand.

Does anyone know a good guide or repair instructions for the heat shields? Or maybe there is another repair that requires removing the heat shields and includes instructions? I have a bootleg Vida but sometimes it seems if I don't search for the exact right thing that it doesn't show me what I need.

Thanks!

 

[LittleRedRidingHood]

It looks like the turbo heatshield has been removed from the car.

It's hard to tell from the video, but I would guess it's one of two things:

1. The charge pipe that you're sourcing bolts for
2. The exhaust rattling against one of the under-body heatshields (they basically line the entire driveshaft tunnel

 

[Swede40]

It looks like the turbo heatshield has been removed from the car.

It's hard to tell from the video, but I would guess it's one of two things:

1. The charge pipe that you're sourcing bolts for
2. The exhaust rattling against one of the under-body heatshields (they basically line the entire driveshaft tunnel

First of all, amazing car. I have the abused sedan version of yours.. but I'm working hard to bring it back to it's glory. In the six or so months I've had it I've probably spent 3x it's blue book value in getting it into shape. New clutch, all new suspension, all new cooling system, new tires, all new belts, and on and on. It runs great, but I keep finding things that concern and puzzle me, and as I fix stuff new noises keep popping up.

Thanks for catching that and the suggestions. I'm about to put in a big order for misc parts that I need to replace and are missing, such as the bolt and the replacement intercooler pipe.

Here are more pictures looking down in the engine bay. Can you tell anything else about what is missing or needs replacement based on these photos?

 

[LittleRedRidingHood]

Thanks! I still have a ways to go to get mine up to a satisfactory standard, too - just a bit at a time!

In your photos, you can tell where the turbo heatshield would have gone - the end of it bolts to the turbo in the bolt hole circled below, and the front bolts onto the exhaust manifold in 3 places. I run my car without the turbo heatshield with no issues - a number of other owners do as well.

For the heat shields I was referring to, you'll need to get under the car and just follow the exhaust and driveshaft back - rattle all of the aluminum heat shields along the way - they should all be a light silver in colour, some are a very light weight metal, some are a heavier weight.

 

[Swede40]

Thanks! I still have a ways to go to get mine up to a satisfactory standard, too - just a bit at a time!

In your photos, you can tell where the turbo heatshield would have gone - the end of it bolts to the turbo in the bolt hole circled below, and the front bolts onto the exhaust manifold in 3 places. I run my car without the turbo heatshield with no issues - a number of other owners do as well.

View attachment 182176

For the heat shields I was referring to, you'll need to get under the car and just follow the exhaust and driveshaft back - rattle all of the aluminum heat shields along the way - they should all be a light silver in colour, some are a very light weight metal, some are a heavier weight.

Do you know the part number of the turbo heat shield that is missing in my car? I'm having an impossible time trying to find it and I don't know what it looks like since I don't have one.

Is it one of the numbers in these diagrams?

Or maybe it's #6 in this diagram of the turbo parts?

The only other heat shields I can find are under the trunk.

 

[LittleRedRidingHood]

Yes, you got it.

You'll need 3 of #7 and 3 of #8 or #9 (not sure which one - a dealer could tell you), and 1 of #10 (I think). Would be great to get someone else's input on the bolts / hardware.

 

[Swede40]

Yes, you got it.

You'll need 3 of #7 and 3 of #8 or #9 (not sure which one - a dealer could tell you), and 1 of #10 (I think). Would be great to get someone else's input on the bolts / hardware.

Thank you! So I'll get the heat shield, 3 springs (#7), and then 3 of #8 since they are nicely labeled "Heat Shield Bolts." #10 is tricky because while it's in the diagram, none of the parts websites list it below with a part number. Maybe it's the same as part #14, the "Water Pipe Screw."

#9 is an Air Pipe Screw so that probably isn't the one I need.

Edit to add link: Turbocharger & Components for 2006 Volvo S40 | TascaParts.com

 

[LittleRedRidingHood]

#14 is a banjo bolt (allows water to pass through to/from the turbo), so that's not it.

 

[Swede40]

#14 is a banjo bolt (allows water to pass through to/from the turbo), so that's not it.

I found this old post that may be related: What did you do to your car today?

Although it's a different model, those are the same parts that are in the parts diagram for the P1 S40 T5 AWD M66. (EDIT: It appears to be a V50 and was posted in this forum so hopefully those bolt references are correct)

So, perhaps that mysterious bolt #10 is part of another system and not the heat shield.. Hopefully when I get in there, I'll find it's not missing. Fingers crossed.