I thought I would post this so that it might help someone in this forum if you are experiencing some of these same issues: I have a 2003 s60 and my car has just starting stalling constantly when at a stop or turning corners, in addition it would also surge and stall when at a light...took it to a local import repair shop and it seem that in the intake is a box, its call an Oil seperator well it was completly covered with carbon and that seems to be the problem so the box is being replaced as well as the hoses due to a vaccuum leak all the parts are around $150.00 and I am hoping labor doesnt kill me but I hope if someone is having this issue this thread helps!

 

pats, just a clarification, is the box under the intake manifold? If so, then it's the flame trap w/c gets clogged and needs to be replaced at about the 100k mile range. Labor could get expensive but your car will def. run better. Forget about the labor cost, just enjoy the ride.

 

Your PCV system would have to be VERY restricted to cause constant stalling and surge.
Be careful with "import shops," most of them are incompetent when it comes to Volvo drivetrains.
Best of luck to you.

 

BBamKudin yes it is under the intake, and it was covered with carbon build up, they obviously replaced the box as well as all the hoses total parts = $150-$170 and then labor total cost was $395.00 which I am happy about however he did tell me that I could after this is fixed I could still have a problem because because of the code which was for one of my sensors! keeping my fingers crossed that this fixes my problem :-)

 

pat, have the car diagnosed to determine what the DTC is then post here so members can help you out. Don't just rely on what the shop says. Go to your loacal auto parts store and have them read the obd and they'll tell you the codes. They could suggest a fix if they're knowledgeable. They could even erase the DTC and see if it comes back.

 

BBamKudin codes are gone and should not come back, the car runs amazing....now the starter solenoid is going on me so I am going to replace the starter before I start to have major problems with it.....I went to fcpgroton and the starter will cost me $199 not sure if I am able to find it cheaper, I use fcp and want and only use genuine volvo parts...nothing aftermarket and fcp offers life time warranties on a lot of their parts....so for now all is well the cars mpg should improve and the increase in pickup is amazing! I hope this thread has helped other members!