Text
CSC = Customer Symptom Code
DTC = Diagnostic Trouble Code
DIM = Driver Information Module
PZEV = Partial Zero Emissions Vehicle
ECM = Engine Control Module

Note! If using a printed copy of this Technical Journal (TJ), first check for the latest online
version.

NOTE! THIS DOCUMENT SUPERSEDES THE FOLLOWING TECHNICAL JOURNALS:

TJ 24411 dated 2011-04-13
TJ 24643 dated 2011-08-09
TJ 22113 dated 2010-06-30

The TJ has been reorganized to prevent incorrect diagnosis. Piston kit replacements have been
added to prior approval. PLEASE UPDATE YOUR FILES.

DESCRIPTION:
This TJ describes the measures to be taken if a customer complains about low oil level, excessive oil
consumption, white smoke from the exhaust, oil smell, or the yellow warning symbol and the "Engine oil
level low" text message in the Driver Information Module (DIM) on a vehicle with the short Inline 6-cylinder
(Si6) engine. The chassis range is not tied to any specific symptom or product modification and is left openended for this TJ since the diagnostic information is useful for all vehicles with the Si6 engine.

With this TJ, Volvo Cars of North America is applying its prior approval process for any claims
submitted during the diagnosis of oil consumption on an Si6 engine in a Model Year (MY) 2010,
MY 2011, or MY 2012 XC90, XC70, XC60, S80, S60, or V70. The Prior Approval Department must
be contacted for all warranty engine and cylinder head replacements and warranty cam cover
reseals for the Si6 engine in a Model Year (MY) 2010, MY 2011, or MY 2012 XC90, XC70, XC60,
S80, S60, or V70 vehicle. This applies to all Si6 engines (engine codes 90, 94, 95, 96, 98, 99).

The Prior Approval Department must be contacted for authorization codes for the following
operation numbers and/or part numbers:
21110-0

21014-0
21144-2
Piston kit PNs: 9487401, 9487402, 9487403
This includes cam cover reseal, cylinder head replacement, piston replacement, and engine
replacement. If any questions arise contact the prior approval department.

Authorization codes for the labor operation codes above will only be available via the Prior Approval
Dept. Prior Authorization is not required for customer pay repairs and/or diagnosis related to this TJ,
however this TJ offers fault tracing information for these cases. The technician should refer to the Prior
Approval application on VRC2.

Technicians who need to claim the labor operation above to make a repair on the vehicles in the
TJ header should contact the Prior Approval Dept before making any repairs by submitting the
online form on VRC2.

This is not a parts restriction process. Parts availability questions should be directed to the Parts
Retailer Services Department

VOLVO STANDARD TIMES GUIDE (VSTG) INFO:

Operation number 21110-0 - Cylinder head replace - See VSTG
Operation number 28106-2 - Spark plugs kit replacing - See VSTG

Operation number 36004-2 - Software, control module downloading - See VSTG
Operation number 99583-2 - Control engine oil consumption - 1.6 hrs*
Operation number 99584-3 - Control engine oil consumption - 0.8 hrs*

*Claim these two labor operation numbers if the oil consumption check is performed.

Operation number 99400-2 - General check/adjust acc. to TJ -0.1 hrs**
**Claim this labor operation number if the cam cover is removed for inspection. Do not use 99400-2
together with 21110-0.
Operation number 21144-2 - Gasket valve cover replace - See VSTG***
***Do not use 21144-2 with 21110-0.
Operation number 08273-6 - LOF and replace dipstick acc to TJ 24643 - 0.5 hrs***
***Operation number 08273-6 is only to be used when following this TJ (not when replacing the dip stick for
other reasons).
Operation number 08275-6 - Oil level, correct in service lane - 0.1 hrs****
****Operation number 08275-6 is only to be used when the oil is topped off in the service lane and the
customer chooses not to stay for proper diagnosis. Do not use 08275-6 with any other operation number in

this TJ.
- Claims may be submitted under the new car warranty when there is a documented customer complaint
using claim type: 01

- Labor times are valid at the time of release and are subject to change.

To view TJ attachment continue to next page:

§ Volvo Car Customer Service
TJ Instruction
TJ No 24643
Date
April-12
Issue 04
Title

Excessive oil consumption, low or uneven idle, Low oil Level message in DIM

Table of Contents
Overview
Step 1. Engine 94 (MY 2011-2012 Si6 PZEV) only
Step 2. Spark plugs (all engine types)
Step 3. Cam cover
Step 4. Valve guides
Step 5. Engine 96 (MY 2010 PZEV) only

Page 1
Page 3
Page 5
Page 6
Page 8
Page 10

Overview
For all repairs, be sure the parts are available before beginning the repair in order to
ensure customer satisfaction.
This engine type is very sensitive to overfilling because it is hard to check the oil level
with the dipstick in an easy way. This is because the engine oil needs time to settle in
the oil sump and also because the dipstick can be turned around causing the indicated
level to be different. The car must be parked on level ground when measuring the oil.
The engine should be driven at normal operating temperature on the road (not idling) for
30 minutes. The engine must then be left for 15 minutes before noting the oil level.
It is also important to note that the dipstick changed in Model Year (MY) 2007 and MY
2011 vehicles. The different part numbers (P/N) for oil dipsticks have chassis breaks in
the VIDA parts catalog. Refer to the catalog to identify the correct P/N. For vehicles
with engine code 94 see page 3 concerning the dipstick. When refilling the engine
with oil its imperative that the correct fill amount be used.
Before diagnosing an oil consumption complaint, always check for external leakage on
and around the engine, especially around the cylinder head / cam cover / timing cover
area. If external leakage is present, repair instructions in VIDA shall be used. If no
external leakage can be detected, proceed to follow the steps in this TJ.
If a customer complains about high oil consumption, poor idle quality, white smoke from
the exhaust, oil smell, and/or a DIM message "Low oil level" or "Oil level low" AND low
oil level is confirmed on the dipstick (unless just topped up), then proceed as described
below. If the "Low oil level" or "Oil level low" message is on in the DIM but the oil level
on the dipstick is not low, refer to TJ 24382.

Gathering information from the customer and testing for oil consumption
Note! To confirm an actual oil consumption condition, there is an oil consumption
test in VIDA that can be used as a guide for this, but it is important to note that
the customer does not have to be used for testing. This will only result in a repeat
repair. The reason for this is based solely on customer satisfaction. This is why
this step is so important. If the "Low oil level" or "Oil level low" message is on
AND the oil level is low or the customer had to add oil (and it is now not
overfilled), but there are no external oil leaks, it can be assumed that oil
consumption exists without using the customer to run the full oil consumption
test. For the full oil consumption test, refer to VIDA> REPAIR> Cleaning,
Inspection, and adjustment> Engine with mountings and equipment> Lubricating
and oil system> General> Oil consumption test. See VIDA for oil capacities and
oil consumption limits.
If a customer chooses not to stay for proper oil consumption diagnosis, then Operation
number 08275 must be used whenever oil is added in order to correct a low oil level.
For example, if the customer comes in to the service lane and the service advisor adds
oil and sends the customer on his/her way, this must be documented properly! A repair
order must be created and Operation number 08275 must be used. Do not use
Operation number 08275 if the vehicle is in for proper oil consumption diagnosis
according to this TJ. There are other operation numbers in this TJ for accurately
tracking these vehicles. When claiming Operation number 08275, the warranty text
must include how much oil was added and how many miles the vehicle has been driven
since the last time oil was changed or added. It is very important to retain accurate
records of oil consumption and/or oil level checks on the customer's vehicle and these
records must contain details including mileage between adding oil and how much oil
was added. If a customer or an independent repair facility adds oil before arriving at the
Volvo dealership, the customer needs to be as accurate as possible about when and
how much oil was added.
If the test shows normal consumption values it is very important to explain to the
customer how to check the oil level, how much to add, and what is the correct type of oil.
If oil consumption is confirmed, proceed to follow the steps in this TJ.

Step 1. Engine 94 (MY 2011-2012 Si6 PZEV) only
This step is only valid for engine 94, which was introduced in model year 2011. The
customer may experience unexpected engine oil usage for the distance covered, e.g.
5,000 miles, the yellow warning symbol may be lit and the "Engine oil level low"
message may be displayed in the DIM. The spark plugs may be equally dark (see Photo
1 below).

TJ 24643
Photo 1

A new piston and oil control ring was introduced into production at engine date
301011B21530 (DDMMYYxxxxx). Follow the steps below for the service solution for
engines built up to this date.
Print out DTCs using VIDA. Remove all spark plugs and compare the deposits / colors
of each plug. If some plugs have a lot more soot than others, see Steps 3 and 4. If plugs
match Photo 1, follow the steps below. Regardless of what the plugs look like, the latest
ECM/TCM Upgrade should be performed (after the proper repair is carried out) before
releasing the vehicle to the customer.
• Perform an ECM Upgrade according to VIDA. Note that after this download the
customer may notice a slight difference in transmission shifting since the ECM and
TCM Upgrades get downloaded together.
• Replace the engine oil dip stick with P/N 31251037
• Exchange the engine oil and refill to a volume 0.6 L (0.6 qts) higher, making the
total oil fill volume 7.4 L (7.8 qts). Confirm that the oil level is up to the MAX mark
on the new dip stick.
• Install a decal P/N 31349543 showing the new engine oil volume. Clean with
isopropanol P/N 1161721 and apply the sticker according to the Photos 2 and 3.

Photo 2. XC70 / S80

Photo 3. XC60

If a vehicle with engine 94 returns with oil consumption after downloading the latest
ECM software, then check cylinder leakdown according to VIDA. If it is confirmed that
the oil is being consumed via the piston rings, a new piston kit has been created to be
used as a service fix. The new piston kit uses a new oil control ring which will not fit in
the original piston ring land.
Piston kit PNs are in the VIDA parts catalog. Replace the pistons and piston rings
according to VIDA.
Pistons Kits are on prior approval. For all components that are on prior approval,
the online form must be filled out. For piston replacement be ready to show that
there are no other reasons for the oil consumption.

Step 2. Spark plugs (all engine types)
Print out DTCs using VIDA. Remove all spark plugs and compare the deposits / colors
of each plug. If Engine Control Module (ECM) DTC P030000 and/or ECM P030600 are
present and if spark plug # 6 and in some cases also # 5 show significantly more
deposits and have more soot than the other cylinders, it is very likely that the engine, at
some point, has been overfilled with oil or is consuming oil via the Positive Crankcase
Ventilation (PCV) system. The DTCs indicate that oil has been consumed in the engine
causing misfires (above mentioned DTCs).
Perform a cylinder leakage test according to VIDA to determine whether the oil
consumption is coming from an area other then the cam cover. If a leakage test proves
that there is cylinder leakage from an area other then the cam cover, follow the
information in the oil consumption test page in VIDA.
If the cylinder leakage tests are OK and if the spark plug from cylinder # 6 has more
soot than the others, proceed to Step3. If the cam cover was not properly sealed from
the factory, then this could be indicated by the #6 plug having the most soot, and then
the soot level decreasing gradually towards the #1 plug.
If the cylinder leakage tests are OK, and if both spark plug from cylinder # 6 does not
have more soot than the others, but there is another plug that has more soot than
others, proceed to Step 4.
Spark plug soot level for Prior Approval: Level of soot on plugs (0 = no soot, 5 =
excessive soot), see Photo 4 for reference. A rating of "0" would correspond to a brand
new spark plug. You will be asked to provide this information and a picture of the spark
plugs when submitting the online form to the Prior Approval Department.
Cylinder #1) ___ #2 ___ #3 ___ #4 ___ #5 ___ #6 ___

TJ 24643
Photo 4. Photo examples for soot level reference

Step 3. Cam cover
Remove the cam cover and inspect the sealing surface. Refer to Photos 5 and 6 below.

TJ 24643
Photo 5. For reference only, not a valid check

TJ 24643
Photo 6. Check method for cam cover sealing surface

If the sealing surface is discolored by oil as shown in the photos, it is most likely that
there is a leak between the cam cover and the cylinder head in the area facing the PCV
channel connecting the breather box and the PCV gallery. If this is the case, the valve
guides should still be checked according to Step 4 before continuing. After checking
according to Step 4 (as long as the same cam cover and cylinder head will be reinstalled), the cam cover must be resealed according to VIDA. To get claim approval,
contact the Prior Approval Department.
If the sealing surface is not discolored by oil as shown in the photos, continue diagnosis
elsewhere in the engine. The cam cover should be resealed according to VIDA prior to
re-installation, as long as the same cam cover and cylinder head will be re-installed.
The cam cover seal was improved at engine production date 15041000001
(DDMMYYxxxxx). The production date, in this case April 15, 2010. The engine serial
number can be found using VIDA "Vehicle Details".
If the discolored sealing surface is found on engines built after the engine
production date, please inform the Prior Approval Department when you contact
them for claim approval. Make sure you have the engine serial number when
contacting prior approval.

Step 4. Valve guides
Note! It is very important to realize that there may be the presence of engine oil in
the intake ports without an actual valve guide leakage. Using Automatic
Transmission Fluid (ATF) for color differentiation is an effective way to verify if
there is or if there is not a leak between the valve guide and the cylinder head.
Cylinder head replacements should NOT be based on assumptions.
Valve guide leakage has been seen on vehicles with an engine build date before
040511B01272. Valve guide leakage is most commonly found when a customer
complains of excessive white smoke from the exhaust. However, these tests should be
performed on all engines with oil consumption to be sure the valve guides are OK.
These tests check if there is oil leakage between the cylinder head casting and the inlet
valve guides.
Look at the spark plugs in Photo 7 below. If the valve guide is leaking in a cylinder, the
corresponding spark plug will have more soot than the others. In the example in Photo 7,
cylinder 2 is consuming oil.

TJ 24643
Photo 7

Remove the cam cover and test each valve guide using ATF. The test below should be
performed:
Note! Use safety glasses! Remove the valve tappets. Plug all but one intake port, all
injector ports, and the PCV inlet. Starting with the intake port that corresponds to the
spark plug with the most soot, apply air pressure to one intake port at a time using a
plug similar to those found on emissions testers. See Photos 8 and 9, left. Look at the
base of the valve spring and check for ripples or bubbling in the ATF as you apply light

air pressure. If the ATF ripples or bubbles, then replace the cylinder head. To get claim
approval, contact the Prior Approval Department.
Plug or tape closed
the intake ports,
injector ports, and
PCV port

TJ 24643
Photo 8. Note that the cylinder head is removed in this photo but this test should be performed on
the vehicle.

Plug or tape closed
the intake ports
and injector ports

Look for bubbles or ripples
here while applying air
pressure
Plug this PCV port

Photo 9

Step 5. Engine 96 (MY 2010 PZEV) only
If all diagnostic steps have been followed on a vehicle with engine 96 and the root
cause of oil consumption has not been found, then it is possible that the engine will
need new piston rings.
Check cylinder leakdown according to VIDA. If it is confirmed that the oil is being
consumed via the piston rings, a new piston kit has been created to be used as a
service fix. The new piston kit uses a new oil control ring which will not fit in the original
piston ring land.
Piston kit PNs are in the VIDA parts catalog. Replace the pistons and piston rings
according to VIDA.
Pistons Kits are on prior approval. For all components that are on prior approval,
the online form must be filled out. For piston replacement be ready to show that
there are no other reasons for the oil consumption.