Thanks for all the help and advice, it seems the problem has finally been cleared. After cleaning the EGR and having permanent lack of boost (due to me failing to re-attach a vacuum pipe.......) I called the AA who diagnosed a shot turbo. I took the car to an independent Volvo specialist to do tests and they diagnosed shot engine mounts. These were replaced and paid for out of breakdown insurance I had through AA.
When I took the car out and tried it the same fault came up, this was repeated initially on the motorway when I took the car on holiday all loaded up but instantly cleared and has been trouble free ever since; this included going up some really challenging hills in north Devon (Portlock hill) with a packed car and packed trailer so definitely fixed.
The fault that happened after the engine mount replacement may have been a partially blocked vacuum due to lack of vacuum pressure previously I guess. Just very relieved that it all seems OK now.
Thanks again for taking the time to help me through it.
Glad it's all sorted for you.
Yes, that's the one; Porlock rather than Portlock. Had to overtake a belching old van that was struggling whilst we were pulling a loaded up trailer, top box, five people plus two dogs in the car. Time trial wouldn't have been very impressive for a hill climb but I was well chuffed it made it up there accelerating strongly. Quite a relief! More concerning were the smoking front disc pads after making it down on the way home...
cherry1809 (Monday 18th August 2014)
Just FYI, I had exactly the same issue with my 2005 S60 D5, I replaced the TCV, the flexi hose to the turbo (common fault) and changed the fuel filter, but it ended up being a VERY sooted up turbo. This was stripped and cleaned to release the VNT vains and that cured the problem.
Hope it stays error free
Thankyou, Goodnight....much love
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