How to solve a problem with EGR valve : Volvo 2.0 D4 ( P04D900 , P241300 )

one very big minus is the silicone which is not needed there. you should buy and install new gaskets

Good job. I tried to clean cooler with different chemical agents I could get at shop, but eventually brought it to car wash and used strong water current which worked for me excellent.

Great job. Thanks..

It's so fantastic!

Question, how long after assembling the egr back should you wait until you start the vehicle again for the sealant to cure?

Very helpful tutorial, I had a very clogged EGR on my V60 and it has been of great help watching how to disassemble and clean it. The two T40 torx bolt behind the EGR cooler were quite difficult to get to, nearly lost hope. However I watched another video that explained that the right size of those bolt was a T40 so that helped making sure I was using the right size. I would also recommend prior to starting the process to spray some penetrating oil on those screws, so by the time you reach to disassemble them, they'll be easier to remove. EGR cooler was very dirty (68k miles on a 2017 car) and it took few days and multiple soaking to cleaned it up. Some people uses also ultrasonic cleaners, I've not tried as I don't have one, but it could be an alternative especially if you're planning to do few of them. Volvo quoted £1500 to get it sorted and didn't want to do any goodwill. After putting everything back and deleting the code, it has not come back and everything looks alright. I'll try to update if anything changes.

I have just finished the cleaning and remounting of my EGR valve (I have 140 000 km). First I would like to thanks you because you gave me evidence that it was not too difficult. Second through this I notice two issues: a) My EGR valve was one mounted with 2 bolts (the 3rd one below was not there), b) the pipe which was controlling the pneumatic actuator to by-pass of not the EGR cooler was squeezed and therefore was no longer allowing by-passing the cooler when the motor is cold (which is probably why I noticed a lot of soot in the cooler as well as in the gas inlet pipe. My EGR cooler was almost clogged, your trick with acetone worked fine (I kept a picture). I followed strictly your procedure except one. i.e. I removed the exit pipe of the EGR going back to the admission inlet. This eases the physical access to the EGR valve, allows cleaning this pipe (it was very dirty dust and soot), and allows also a small access to the admission of the engine (for visual inspection) and allows to remove partly with fingers soots.

I meant tuto (the automatic correction fooled me)

Thanks a lot for your auto. It is very well done with clear visual and verbal explanations in proper English. Keep going.
Jean-Claude

Im getting a P00BC MAF error. I monitired the EGR valve on the app while driving and it stayed at -1.52 and hardly moved from that, so potentially an EGR valve stuck. Im going to get it mapped out, does the EGR delete remap also make the EMAP pipe redundant? Or will the EMAP pipe continue to operate?

Do you live in Germany?
Can you help me plz?

Hi
Do you need to adapt EGR after cleaning?

Great tutorial and very thorough mechanical skills. Has anyone tried to gut the mesh on the EGR cooler and effectively remove the cause of clogging the system in the first place? Cheers

środek do czyszczenia silników mógł pomóc bardziej, również do kominów oraz do piekarników ;) pozdro

Had the faults listed for a while and eventually got round to completing this cleaning process following your video which was a great help. Cooler was blocked and so far so good 👍

What do you think about using a steamer for cleaning the cooler?

Very beautiful video well don

I wish I had the tools to do this myself… in my local volvo workshop they charge 300usd for an inspection, and 500usd for a new part + handwork… I’ll try borrowing tools to do this

Thanks, about to attempt this having watched your disassembling once already - seeing what needs to be removed and where all the fixings are is super helpful - unlike VIDA which basically shows 4 steps and magically the EGR assembly is removed 🤦‍♂️

One question - how on earth were you able to get to the 3rd EGR bolt at the bottom with all the pipework in the way 😮

Update: Well I managed it eventually - my cooler was disgusting, I tried the acetone method which was pretty good, but then realised that there was too much caked on crud inside. A degreaser I had lying around also worked really well - Bilt Hamber's SurfaceX HD which did a great job dissolving a lot of the oil. After around 6 soakings and rinsings, some of the channels were still blocked so I used some thin wire (the outer steel cables from armoured cable) to dislodge any hard bits - after another 3-4 overnight soaks and rinses the water is finally running clear 😵‍💫

Hi, thank you for the well explained tutorial. I followed it but sadly, my EGR valve is broken (actuator not moving freely).
Just a little tip for the cleaning part. I've used oven washing detergent without caustic soda (not good for aluminum). Here in France you can find a product called "decap four" by henkel, the green bottle one named "confort".
It is really efficient.
Goodbye mate!

EGR systems should be taken off all cars they make carbon problems which then in turn makes gas problems smoke etc and poor performance low MPG should be put in the bin

do u need to unplug battery before doing these steps?

Excellent. Many thanks for the very clear to understand procedure.
Keep up the great work.

Thank you for taking the magic and worry out of sorting out my egr problem. Worked a treat, clear video with excellent description. One suggestion if doing this you could slot out the bottom bracket from the left so the you only need to loosen the bolt and won't drop it when replacing the egr cooler. That bolt can't be seen or felt and is hard to locate. I tried slotting it from below but that didn't work due to lack of clearance I couldn't lift it up far enough. Great job saved me a packet!

Today had low oil recently, and today engine light. Went to Volvo for oil, topped up, car had a micro engine stutter on way. My light remains on.. Volvo want £££ to check so I bought myself a reader for tomorrow. I’m curious what app you used and how you were able to test the valve manually? Thanks.

Thank you for the video❤

For anyone that doesnt find acetone,i tried with stove cleaner(the one with lye or caustic soda) and it works brilliant.

Great!

Hello from Finland. Great video. Now I can try it.

Is this the 5 cylinder or the 4?

Following you video I have just completed cleaning my EGR, it was worse than yours,

but my question is what was the name and model of you diagnostic machine???

Great video, thank you.

Awesome guide. Very easy to follow! My egr is super clean now but unfortunately the valve is still temperamental in movement and very stiff! I’m going to have to buy a new one but at least I can fit it myself

Just blank

Perfect thank you 😊 pieknie pokazane jak powinno sie naprawiac samochod brawo

What is the torque used for tightening bolts in this process?

Werkt niet . Vervang de hele zooi . Bespaar je de ellende .

How did you dry the unit after cleaning?

I love the fact that the wrong EGR-Valve/Cooler combination is fitted.. you shouldn’t be needing to use a threaded bolt with a nut on the other side.

Can I use Ultrasonic cleaning machine to cleanr EGR Valve & Cooler? Was thinking of using 10L Vevor Ultrasonic Cleaner with Allendale Engine SOlution....Great video by the way. Thanks.

Very nice video...👏🏼👏🏼👏🏼

Excellent

Do you know if the EGR valve motor return spring is supposed to close the valve as mine is staying open around 2mm, if I close it completely by hand the engine idles better, TIA

Hej, miałem czyszczona chlodniczme egr, ten sam model i silnik. Teraz po jej wyczyszczeniu ubywa mi gdzies plyn chlodniczy. Po odkreceniu korka od zbiornika płynu ucieka powietrze i plyn wraca do prawidłowego stanu. Jakieś pomysły dlaczego tak moze być?

Great video man. I might try it myself also now lol

Thank you for this .
Engine warning light came on and fault code was reported to Volvo on our 2014 V60 D4 they said EGR needs replacing.
We have been quoted £1700 by Volvo to replace EGR.
Absolute disgrace to be charged this when it's a known design fault.

Just bought a 2015 Volvo V40 D4 SE LUX that started when it went to auction and then didn't start when they went to move it again. Tried discussing it via email but were n't too helpful. Watching your video makes me think it has the same problem. I can get out of it costing 600 for them to put it through auction again, or take a 6 grand chance. Any
help would be well appreciated. Excellent video mate.

człowiek ledwie zaznajomiony z mechaniką zrobi to krok po kroku czy lepiej oddac do mechanika? pozdrawiam