The Car Edition has diagnosed and resolved a severe loss of power and top-end oil leak on a 2010 Volvo XC60 five-cylinder diesel.
Initial investigation revealed a leaking rocker cover assembly, which on Volvo’s five-cylinder diesel unit doubles as the intake manifold. A fracture along the plastic seam caused a major boost leak alongside the external oil mess.
After removing the fuel lines and marking the coded injectors for correct reinstallation, the team unbolted the failed plastic cover. They also identified a brittle intake pipe with sheared mountings that had previously been bodged with adhesive.
An original Volvo cover assembly was fitted with a fresh gasket, torqued in a spiral pattern to 10 Nm. Clean copper washers were dropped flat into the injector wells before securing the clamps to 13 Nm.
The job concluded with cleaning a heavily fouled MAP sensor, fitting a replacement intake pipe, and checking live data to confirm boost pressure was restored.
