Reminder: videos and articles you find on the web all belong in the off-topic section, even if they are about Volvos.

Sourcing electronic turbo actuator for 2009 XC90 D5

xc90DB @xc90 Canberra/ Sydney northern beaches

Hi all, It seems like my 2009 XC90 D5 has a turbo electronic actuator problem. The part isn't sold separately by Volvo but there are aftermarket ones online from China and Europe for around $120-$200. 'G-40' is the most likely part number I see online for a 2009 but it's not completely clear - others are G-25, G-27 etc. Does anyone know how to work out reliably what the part number is without removing the old one first? Thanks, Dave.


  • xc90DB @xc90 Canberra/ Sydney northern beaches

    No, just behaving erratically. Most mornings when the engine's cold it's dumping boost somewhere weird. You can hear it through the air box and car goes into limp mode. After a short drive, turn off the engine for 2 or 3 minutes, restart and it's all good. We've fixed swirl flaps, de-carbed the EGR and intake, and done numerous scans with the Volvo reader, this seems to be where it's all pointing.

  • Ecu setting a code on it as well?

  • xc90DB @xc90 Canberra/ Sydney northern beaches

    Yes - and a text readout indicating boost problems.

  • Assume you checked the L shapperd intercooler pipe under the block that is super common failure?

    In short... the vgt actuator pretty much never fails

    Other sensors fail in was that give plausible but non accurate values which causes the ecu to acuate the vgt and then whine about the part not broken

  • xc90DB @xc90 Canberra/ Sydney northern beaches

    Thanks. I'm relying on my mechanic for this; he's good with Volvos. He also doubted the actuator was the problem but has come around to that view. He replaced boost sensor in case that was the issue.

    I did see this thread for a case of faulty actuator.

  • xc90DB @xc90 Canberra/ Sydney northern beaches

    This link is interesting about rotary electronic actuator problems - I have the intermittent low pressure and over boost symptom -

  • xc90DB @xc90 Canberra/ Sydney northern beaches

    Does anyone happen to know the 'G' number for the actuator on an Australian '09 D5? Seems like it might be 'G-35'.

    Cheers, Dave

  • xc90DB @xc90 Canberra/ Sydney northern beaches

    Found this quote re. G-35 actuators from XC90s (2002-2013), on a website selling replacement units.  "This electronic turbo actuator is a common failure for this vehicle and will cause the engine to lose power and the engine will be forced into limp mode. 1517 – Turbo Overboost, 1507 – Turbo Control Pressure Too Low and 1540 – Turbo Control Pressure Too High are common fault codes found when scanning the vehicle with diagnostics."

  • Ex850RSnoopy @Ex850R Somewhere Over the Rainbow. Melbourne.
    edited August 6

    Did your mechanic check the lower intercooler boost hose?

    Philia Bear is a Volvo trained Technician and he gave the diagnostic information clearly.

    The lower boost hose is the most common problem with this model in Australia, it cracks/splits and sounds like boost leak (which it is) and the system freaks out. You need to squeeze the hose.

    Then again, as it's a common failure, just replace it as a matter or regular maintenance.

    This forum has members who are Volvo trained techs from Europe and USA and locally trained Volvo techs and as a group have worked on Volvo of all era for a long time.

    This is why the Ozvolvo is the resource that even folk in other countries use for their issues as well.

  • xc90DB @xc90 Canberra/ Sydney northern beaches

    Thanks Snoopy. I do appreciate that Ozvolvo is fantastic resource.

    I'm sure my mechanic will have checked that boost hose. He's extremely well regarded in Canberra and beyond with respect to Volvos, and he's had two or three looks at my problem. But I will follow up with him about it to be sure.

    One thing about my issue, which is strange to a non-expert like me, is that the sound effect coming through the air box, and the car going into limp mode, goes away after a short drive and restart and doesn't come back until the motor has gone cold again, ie usually overnight. I have no idea whether that would be consistent with a leaking boost hose but i'll be very happy to save the money and the trouble if that turns out to be the problem.

  • if your in ACT

    its worth having @timbo at Ike's motors look at it since he is a volvo specialist

  • xc90DB @xc90 Canberra/ Sydney northern beaches

    Thanks Phillia. Yes, it's Tim and Ike who have been working on the car. Their most recent diagnosis with scanner points to the actuator. But they're not 100 percent certain. So I'm trying to find the correct replacement, which will cost $100-200 - instead of spending $2000+ for a whole new turbo with actuator.

  • Ex850RSnoopy @Ex850R Somewhere Over the Rainbow. Melbourne.

    Well you are in good hands, Tim is one of the great people on here!

  • I don't know of anyone who has ever replaced just the electric motor

    The thing that is bugging me is if the motor is position calibrated via internal firmware from the factory or if the car just works it out on its own

    E.G. on any BMW with a diesel and VGT turbo post ~2006 the electric actuator is calibrated using an external bench device, there are piles of them in Europe but no one in australia with the tool to do a calibration if you need to seperate the motor from the hotside housing

    on the other side of things... something like a HE351VGT as used on a pile of dodge cummins motors just does a quick cycle calibration every time its powered on and could care less how many times its apart etc...

    @timbo is there a software module to install or calibration test to run post tubo replacement? if not then I would assume factory calibrated and just replacing the motor is out

  • xc90DB @xc90 Canberra/ Sydney northern beaches

    I see that @COLBK reported replacing his turbo actuator in 2020 - I think the calibration was done with vida(?) Another case in the UK is here:

  • Ahh ... timbo confirmed there is a calibration in that thread

Sign In or Register to comment.