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Discussion Starter · #1 ·
I've been struggling with an issue for months now with my '05 S40 T5. I've taken the car to the dealership and mentioned this issue each time but I'm not sure if they don't care, but they never seem to hear the problem. Then I took it to my tire place and they even mentioned it to me, lol.

Anyway I'll let the video do the talking:
http://www.youtube.com/watch?v=Ruy9bl1Yg4E

Any ideas of what that noise is that you hear clearly @ 0:03 - 0:05? It continues most of the video until the revs come down but you really here the specific noise at those times. That being said, I here it on cold start until the revs come down about 20 seconds after start.

I also here it at WOT between about 2200 - 3500 RPMs. It doesn't always make the noise but when wet outside, it seems to be more pronounced.

Any thoughts or help for me?
 

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I have no idea if our cars have lifters in them but that is what my old car used to sound like at start up when it was cold until the oil moves around. Again not sure if we have lifters or engine valve lifters that is what reminds me off.
 

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What type of oil do you have? I'm dutch so i don't now the english word for it but we call it "klepstoters".
The mechanicals that drives your valves seems not to get enough oil. I think your oil is to thin of type. is it 5w30?
But i'm not a volvo specialist, so maybe someone else had a opinion?
 

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sounds to me like either a lifter or valve....


BTW what is your exhaust set up? it sounded AWESOME.
 

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The T5 doesn't have hydraulic lifters... Pure mechanical power... So that noise will be some kind of issue there. Could be a cracked exhaust header (my mum's S80 has that too and it sounds kind of like that).
 

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The T5 doesn't have hydraulic lifters... Pure mechanical power... So that noise will be some kind of issue there. Could be a cracked exhaust header (my mum's S80 has that too and it sounds kind of like that).
Hard to say what exact noise you are referring to. My initial thoughts were the same as daim. A cracked or warped manifold will give that pulsing exhaust noise on cold start-up. As the exhaust warms it expands & the small leak is closed off. Look for a broken exhaust stud, poor seal at the turbo, etc.
 

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I would run seafoam through oil hard and oil change/filter within a few days with good full syn. that will clear our buildup so check filter after about 100 miles and that will tell you how dirty it was.

its really hard to tell from your vid, but exhaust leak could be the issue. Doesnt seem right to me though, but check manifold when cold
 

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Had more or less a similar noise a couple of summer ago, found two of the downpipe bolts missing.. with only one bolt holding it there was a leak but very difficult to tell unless you get under the car. Worth checking.
 

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i just wanted to type that. Today i hear a noise, when i checked where the noise was coming from i saw that one bolt was missing and 1 was very loose..
ordered new bolts they where €4,50 a piece.
 

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Discussion Starter · #10 ·
Thanks

Thanks for all the replies. Running Royal Purple 10w30 for those questions with oil.

The down pipe responses & header responses seem about right because the noise is sometimes there around 2500 - 3500k RPMs under WOT, more so when it is humid out. So some sort of air leak when the turbo is really spooling makes sense.

@goddamnswede & @Bas_T5

Where specifically are the bolts you are referring to? Under the car it sounds like? The noise sounds like it comes from right where the down pipe comes out close to the firewall. However I've never been under the car so I'm just curious where you are both referring to with the missing / loose bolts.
 

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You are right, you need to get under the car. Remove splashguard under engine and follow the downpipe up to engine. You will see 3 bolts holding it to the manifold/turbo, if they are all there and snug fitted youre problem lies elsewhere.
 

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I would agree with them, it sounds a lot like an exhaust leak, albeit a small one. Good luck, let us know what you find out.
 

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yes the 3 bolts that fit the dp on to the turbo.
 

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Discussion Starter · #14 ·
Gave the downpipe tightening a try since the weather was nice this weekend. All 3 bolts are super tight. I can't even make them a hair tighter. It sounds like it can still be a problem with the seal though from reading the posts above.

When accelerating at WOT right when the turbo begins to spool, the noise can be heard and is quite loud. The weird part it that the noise is random when accelerating at WOT. It may do it when the engine is cold one day while not the next. The same when the engine is warm, it may or may not do it.

Thanks for the input. I may try the dealership one more time before giving up on this s40.
 

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Long gone thread it seems but I kind of think it might be the exhaust manifold. Very pronounced valve noise. Off with OTE pipe, then 4X13mm bolts holding the heat shield, remember where they go, the two to the left (when in front of engine) is spring loaded. Check the manifold nuts. Recently found 4 of mine finger loose, one was actually 3-4 full turns out.
Retighten from the center out if loose. Some may chime in with torque spec..
It certainly made my engine bay a lot quieter
 

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Well... my mechanic checked and swore there were NO exhaust leaks. Finally I asked him to go check torque on all of the manifold nuts. Turns out three were loose and one broken off. He is having to drop the engine to drill out the broken stud. So that was my reason for having the same sounds as in the video above. I have had to replace the exhaust manifold gaskets and studs twice on my 2001 C70. Now I have the same problem on my wife's 2006. Seems Volvo still has not figured out how to attach a cast iron exhaust manifold to an aluminum cylinder head. Ugly!
 

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Discussion Starter · #18 ·
Long gone thread it seems but I kind of think it might be the exhaust manifold. Very pronounced valve noise. Off with OTE pipe, then 4X13mm bolts holding the heat shield, remember where they go, the two to the left (when in front of engine) is spring loaded. Check the manifold nuts. Recently found 4 of mine finger loose, one was actually 3-4 full turns out.
Retighten from the center out if loose. Some may chime in with torque spec..
It certainly made my engine bay a lot quieter
That was it! Thanks for the heads up. Now that I think back, I always smelled a tiny bit of exhaust so it all makes sense now.

It only ended up being the one manifold bolt circled below in blue (should have taken the picture before putting the OTE pipe back on). I could only get about one turn tighter but that was enough.

Also any idea where to get a bolt for the OTE pipe circled in red?

 

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If the manifold nuts were loose then the gaskets are shot. Just tightening the nuts will not fix the problem for long.

As for the bolt, mine was also missing - one of those things that lazy mechanics leave out and think the owner will never notice. My indy had a spare and replaced it.
 
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