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puzzling overheating and stalling S80 2010

This car belongs to a friend who uses it to commute to work over a modest mountain highway. This 'mountain' rises sufficiently to cause ear popping between the small town in which he lives and the city to which he is commuting.

The car will overheat and stop running in stop and go traffic on a random basis

He has had it in to a shop and here is what they have found to date. The following was emailed to the owner as to what they have been doing.

"Scanned the car when it was dropped off. No-misfire codes from last time, however only one code logged which is ecm-P061A62. Internal control module torque performance failure. Meaning that the engine computer interprets torque requested through various sensors such as air mass/temp/map/throttle computer ect.. When it sees a difference in torq measurement/request between different sensors it limits throttle position. Symptoms are hesitation/jerky running.
This particular code only logged 3 times out of 60 drive cycles, very intermittant. Possible sources for this fault are any of the 12 different input sensors, such as temp sensor/rpm sensor/airmass/map sensor/engine computer or air leaks.
Checked service bulletins in regards to this code, there was a recall in the states for this particular code causing engine shut down at idle/restart issues. Volvo recall RTJ23128-2010-06-29. Doesn’t seem to apply to Canadian models though. I phoned the dealer to see if any recalls are available on the car, there is none available according to your Vin number.
As of right now, I have changed your coils, cleared the codes and let the car sit idling with the a/c on for the last couple of hours with our computer hooked up to it. All parameters are in spec right now, nothing suspect, car hasn’t acted up as of yet.
Couple of directions we can take, one we can keep running the car periodically to see if we can get it to act up here in Cobble Hill[shop location] . It may give us some direction on where to start fault tracing. Second, we can send it down to our Victoria ][city location] to see if they can get the car to act up. Problem is that the car kind of has to start acting up for any sort of repair process, it may run fine for them as well. Third option is updating the engine computer software, about at 275.00 process after subscription/labor/software and see what happens. Keep in mind this would not be a guaranteed fix, car may still act up after software, but at least you could rule it out as an issue."

The shop has access to the Vida Dice software and it has been applied to try and deduce the problem with the car. An intermittent fan was a possible culprit but so far nothing has shown. When the car is at the shop it does not replicate the problem--so far.

Would altitude have anything to do with this? Just thinking of the climb over the small mountain twice a day and really just grasping at straws I must admit.








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All went well with the belt change, ended up changing your serpentine tensioner as well due to the pully making noise when removed. Your engine computer and Central electronic module now have the latest software as well.
Took the car out for another drive today, car drove well on the test drive, however it did die on me when I turned it off and let it sit for half an hour. I had the computer(vida) hooked up when it died, from what I saw in the parameters that the fuel pump duty cycle was @70- 80%, Volvo says duty cycle should be no more than 50% plus or minus 10%. All other parameters I had graphed were in spec. Such as air mass/coolant temp/map sensor. Your cooling fan was at 33% duty cycle so it wasn’t working that hard.
At this point I am leaning towards a fuel pump assembly and a fuel new fuel computer as the computer sits exposed to the elements on top of the fuel tank, when you drop the tank to do the pump, recommended to change both.
I wish I could be 100% confident in this diagnoses, but our master tech has his lab scope with him and he won’t be back till 1st week of September so I can’t scope the actual pattern of the pump. So what I am basing this on is strictly the duty cycle of the pump when it acted up on me.
A new fuel pump is approx 630 from Volvo and a new fuel computer is 530.00. Labor is 400.00 to do both. I would not see both items till Monday next week, so I would have to set you up with a courtesy car if you want to proceed.
I will forward you the estimate including the pump and computer on anther email.



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Both the pump and the PEM are much cheaper in the USA. The PEM is located in the wheel well inside the trunk and should be reliable (no corrosion). Depending on the odometer, the fuel pump may be degraded. But the mechanic should be able to determine the fuel pressure.



VOLVO IS RECALLING MY 2008-2010 S80, MODEL YEAR 2009-2010 XC70 AND MODEL YEAR 2010 XC60 VEHICLES. UNDER CERTAIN CONDITIONS THE SOFTWARE WITHIN THE CENTRAL ELECTRONIC MODULE (CEM) MAY NOT SEND A SIGNAL TO THE FUEL PUMP ELECTRONIC MODULE (PEM). THIS MISSING SIGNAL TO THE PEM INHIBITS THE START OF THE FUEL PUMP. THE DRIVER MAY BE ABLE TO START THE ENGINE IN SPITE OF THE FUEL PUMP NOT BEING ACTIVATED DUE TO RESIDUAL PRESSURE IN THE FUEL SYSTEM. IN SOME CASES, THE DRIVER MAY BE ABLE TO DRIVE THE VEHICLE A SHORT DISTANCE AT IDLE BUT THEN THE ENGINE MAY STALL.

Consequence:

IF THE VEHICLE STALLS IN CERTAIN CONDITIONS, A CRASH COULD OCCUR.

Remedy:

DEALERS WILL DOWNLOAD SOFTWARE TO THE VEHICLES' CEM FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON OR BEFORE SEPTEMBER 31, 2009. VEHICLES IN DEALERS¿ INVENTORY WILL BE REPAIRED PRIOR TO DELIVERY. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
--
Keeping it running is better than buying new



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Thanks Klaus,

I have cut and pasted your answer and forwarded it to my friend who is vacationing in Memphis at the moment, by the way. He is maintaining contact with the mechanic via email

Bob



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