I have an 2004 S60 2.5T 125k miles that I bought about 5 months ago and ever since I've had it there is times that it is really hard to start. It is always after sitting overnight and you have to just keep spinning on it until it starts, sometimes 5 minutes or longer taking short brakes not to burn up the starter. About 3 weeks ago I did a tune up on it and had it scanned which gave me a crank sensor code and mass air flow code which i replaced with new parts from volvo. It did fine up until this week again. The hard start is very random can do it back to back 2 days and then not do it again for 3 weeks. Hot or cold outside does not matter.

It has done it again and I scanned it and got codes 5200 rpm sensor, 138 intake air leak, 6100 cooling fan control module. Ran a compression test after trying to start it for about 5 minutes and got about 60 lbs on 2 cylinders did not check the rest, added oil to them and they did not come up, check timing which is in. So I let it sit over night again and checked compression this morning and it is still hitting about 60 but the more you spin on it the compression comes up. Any Ideas?

 

By the way fuel pressure is good and have spark and injector pulse.