So I've been searching for a Volvo for a while. Found a pretty clean 2003 S40 with 130k miles. Checked it out, drove it (put it through the paces), the guy said he's never had any issues with it and he didn't really want to sell it but had a new Audi and didn't need 2 cars. I buy it and that's when everything went to hell. I drove it home and the next day the CEL came on. I pulled the code and got code P0299 (turbo / super charger under boost) did some research online. Searched for vacuum leaks on the engine and find one. Replaced the hose and the car runs like a champ.
Day 3 cars running great CEL is off. Park it for an hour then head home. On the way home all the lights including headlights start flashing and I can hear a clicking noise under the dash. Goes into what I think is limp mode and has a real hard time climbing a hill. Get home shut it off then restart it runs like a champ again. I feel like I got screwed but now I'm in this car and would like to fix it. I understand as-is but the guy I bought it from better hope I don't see him anytime soon. Any advise on fixes? Has anyone ran into same issues.

 

There were a couple of problems as a usual things to look at.The most serious I remember was a crack on the turbo housing where the waste gate actuator closes the flap inside.If this is the case thats a new turbo for ya.
Easier fixes when the actuator arm gets free and the flap can move on its own.The safety pin just rusts away and the arm gets lose.Also possible exhaust leak between the header and the head.If you can hear some hissing/ticking from there try to tighten the nuts they are known to get lose.If the gasket is out replace it.Do not force them as they tend to snap easily.Use a product to soak them first.
Most easiest thing is when the rubber hose cracks or gets popped off from the pipe on the bottom of the IC or on the top of it.

 

These cars are pretty reliable. Be patient you will work through it. Lots of info on both this forum and the volvo UK forum + swedespeed. I would sign up for all three. Also it sounds like you would benefit from a full code read-out. A generic code reader will get you part way there but for detailed troubleshooting purchase yourself a copy of VIDA/DICE or find a forum member nearby who will read the volvo specific codes for you. Worst case head to dealership and get them to print codes out or write them down. Then report back.
Of note, if i were you I would just replace all the vacuum hoses with new rubber or silicon ones. If one is cracked they are probably all pretty old. It’s a 20min job but it will save you lots of future frustrations. I bought some coloured codes silicon ones which looked nice once installed.

Good luck, keep us posted.

 

Right on thanks for the reply's. I wonder if there is anyone on here willing to help me out with running VIDA/DICE on my car?? The Dealer wants $100 just to check the codes. I've looked up buying a VIDA/DICE set up and already have a laptop to put it on. It would pay for itself with just one hook up. The only problem is its getting close to Christmas and I haven't bought my wife anything yet.

Update: I replaced all the vacuum lines and found a big rubber hose (probably 3/4") running from the top of the intercooler... I think to the intake manifold. No parts store could find it on any diagrams so I went with bulk reinforced rubber hose and some hose clamps. car is running much better but I still have CEL on. I'm going to have it cleared and see if I fixed the issue. Vacuum lines were crumbling as I pulled them off. It obviously had vacuum leaks. Lights flashing seems to be a one time thing, hasn't happened since I posted the first time. I do see the Battery light flash quickly on very rare occasions but it is very rare. I figure the alternator is slowly going out but I'll get it tested and see if its dropping charge.

The car obviously has boost now and I am super happy with it. just need to clean it up, tint the windows, and then start tinkering with it (maybe some coilovers and add a little more boost.) that's going to be down the road though for now its a pretty nice driver.

 

ÜRO PARTS 30637166

VOLVO 2003 S40 1.9L L4 Turbocharged Fuel & Air Air Cleaner Intake Hose

2003 VOLVO S40 1.9L L4 Turbocharged Air Cleaner Intake Hose | RockAuto