Volvo D5 Injector & Intercooler Fix | No More Smoke

Check out this video sponsor and use discount code: OSG www.vehiclescore.co.uk/affiliate/OSG10 Welcome back to Old Skull Garage – Build It 👊 In this episode, I’m fixing a couple of serious issues on my 2003 Volvo V70 D5 (163BHP) — and this one turned into a proper diagnostic challenge. The car recently developed: Hard starting problems Heavy black smoke under load So it was time to get stuck in and find the root cause. 🔧 What I did in this episode: First step was tackling the diesel injectors ➡️ Replaced a couple of faulty injectors ➡️ This immediately improved the starting issue But the job wasn’t done yet… Even after the injector swap, the car was still producing black smoke — which usually means something isn’t right with the air/fuel mixture. After further investigation, I discovered the real culprit: 💥 A hole in the intercooler Because of the boost leak: Not enough air was getting into the engine The engine was over-fuelling Resulting in thick black smoke 🔧 Final Fix: ➡️ Replaced the intercooler ➡️ Restored proper airflow ➡️ Balanced air/fuel ratio And just like that… the smoke issue was sorted 👌 This episode is a great example of how: 👉 One problem can hide another 👉 And why proper diagnosis is key when working on diesel engines If you own a Volvo D5 or any diesel car, this is definitely worth watching. 👇 Let me know in the comments: Have you ever chased a fault like this before? 👍 Like 🔔 Subscribe to Old Skull Garage – Build It 📺 More real builds, fixes & diagnostics coming soon 00:00 - Introduction & The Volvo D5 Problem 00:36 - Demonstrating the Long Cold Start 01:07 - Why Is There Black Smoke? 01:31 - Testing Injector Pulsing by Hand 02:22 - How to Remove Volvo D5 Injectors 03:54 - Inspecting the Old vs. eBay Injectors 04:29 - Pro Tip: Always Replace Copper Rings 05:28 - Fitting the New Injectors 07:19 - Checking Car History with Vehicle Score 09:25 - First Start with New Injectors 10:12 - Troubleshooting a "Chuffing" Noise 11:33 - Finding the Broken Copper Ring 12:57 - Diagnosing the Leaky Intercooler 14:07 - The Verdict on the First Test Drive 15:20 - Next Day Cold Start Results 17:28 - Removing the Old Intercooler 18:54 - Installing the New Intercooler & Pipe 20:29 - Final Test Drive: No More Smoke!