How to solve a problem with EGR valve : Volvo 2.0 D4 ( P04D900 , P241300 )
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- čas přidán 22. 08. 2024
- This video is showing how to solve a problem with EGR valve and EGR cooler in 2014 Volvo xc60 2.0
d4 engine 181 hp. Fault Codes P04D900 and P241300 - First fault is related with low flow of exhaust
gasses, second is general failure EGR system performance. In this video I show you step by step how
to fix this problem saving $$$$, and you can do it with simple hand tools.
Stuff that i used:
To clean EGR valve-
EGR cleaner spray (or carburetor cleaning spray),
Soft wire brush,
For edge surface and gaskets cleaning: abrasive buffs grit (dremel 511s)
To clean EGR cooler-
EGR cleaner spray (or carburetor cleaning spray),
More effective was PURE ACETONE
For edge surface and gaskets cleaning: abrasive buffs grit (dremel 511s)
And engine silicone sealant
Unfortunately i could not find set of EGR gaskets. They are included with new EGR. That's why I used
silicone sealant.
Cars guide DIY assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. Cars guide DIY recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of Cars guide DIY, no information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Cars guide DIY.
Excellent job well done, if only all mechanics were as clean and caring in their work. I'm guessing the 20 dislikes come from Volvo employees
You made this look easy.
Because of your video, I attempted this myself, took me all day, but fingers crossed, it seems to be fixed.
Thank you for taking the time to make this video, it gave the confidence to try myself.
Good luck with yours ;) Regards
Did it solve your problem?
@@sheffcitys2forgedinsteel255 yes, I didn’t keep the car much longer after I fixed it , but no error light ever came on afterwards
@michael oliver that's good to hear,
Thanks for the quick reply mate
Thank you very much for this excellent video !!!
It has made me confident to start doing it myself .
I did it on a complete week-end including the cleaning with pure acetone.
The warning light, so annoying, no longer reappears at all after the reset with my OBD2 reader.
The car is now more punchy, consumes 0.5 liter less per 100km and I saved a lot of money :-) the garage did not want to clean but to put new parts..
Several points to share if it can help :
- XC60 2014 200K km
- EGR changed at 60K km
- EGR recall done ~2years ago (hoses +ECU reprog it seems)- motor warning light appeared 6 month ago
- I've bought the gasket between EGR and cooler on auto-doc Ref 013.630, brand 'Elring'. It fits perfectly and is of good quality
- Step to empty the coolant at 4:50 in the video skiped. I used a cut bottle instead to recover the liquid (~0,5 liter) when removing the hoses.
- the tightening torques can be found on other videos- the step of unscrewing the 2 screws between the EGR and the exhaust pipe is not shown in the video ~6:22. Have you changed your original torx bolts to new ones in yellow color (hexagonal head) ? On my car it has torx screws and I had a problem at this step because I stupidly forced with a Torx30 screwdriver even though it was Torx40. I couldn't see the screw well because the head was oriented towards (and close to) the dashboard; I partially broke the teeth of the screw. I recovered the problem by forcefully pushing a torx40 screwdriver into the screw (with a hammer), it worked.
Voila ! Thanks again and long life to your channel ! ;-)
Hi, Just followed your video and did the job. Your Video and description was brilliant. I had Engine warning light on all the time. I had it checked and it was EGR fault. £1000 for volvo to fix!!! I did it in 5hours plus 24 hours cleaning time. Now all cleaned out and back working. the car feels more responsive. My D4 had only done 47K miles and I could tell the EGR has already been off before because bottom bolt was missing!!! Thanks CG love you.
Good to know :) Regards ;)
I'm also having trouble with my egr on 2.0 d4 r design 2014, garage has quoted me over £800 and that doesn't include labour,
100,000 miles
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.
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 👍
I was replacing EGR valve my self recently at the same engine. Unfortunately in my case that sort of repair was not possible due to faulty electric engine, so I had to replace whole valve. For those who have got same problem this is great movie. Great job.
Same problem on my side. how many miles/km you had on board when happened?
Same happen to me my d2
Hi,
I'm also having trouble with egr and may need to replace it, if you don't mind me asking how much did you pay for it?
As a garage has quoted me over £800 and that's not even including labour
The same thing was needed for me. Replaced it for 600 gbp and the dtc re appeared. Still investigating
Excellent video, the best explanation on you tube tube thank you very much for your help. All the fuss and fear that is on forums makes this job seem a nightmare but it's really just nuts and bolts and cleaning. Thanks very much. 😊
Great video with step by step instructions and explanations, keep up the nice work, love seeing more especially Volvos D4 VEA engines.
Jestem z Ciebie dumny chłopaku! Świetna robota, oby tak dalej. Dziękuje że dzielisz się wiedzą i doświadczeniem.
Good video. Do not be affraid to use high pressure washer. It helped helped me finaly. Soaked in different chemicals but finaly got clean with high preassure washer.
Thanks for the tip! I followed your advised and cleaned mine with the pressure washer. Happy with the result. ;)
Thanx for video. I was following your steps and cleaned my egr, cooler and complete intake manifold today. Was in worst condition than yours. Egr cooler was completly blocked. I used cleaner named "dimer", 2 component cleanser and it showed amazing results. Now car is going much better. Too bad i cant post pics here to see in how bad condition it was..
Great Video. Try oven cleaner for the EGR for 30 mins or so and that should shift the soot!
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.
Brilliant video. All detail no wasted time. Thankyou.
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!
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!
I'd like to think my mechanic had the same level of attention to detail.
But, he doesn't.
They never have. It almost does not matter which car brand we are talking about.
Dzisiaj przeczyściłem egr w moim s80 D4. Mega filmik robiłem krok po kroku. Dzieki
Link please
Thanks a lot for your auto. It is very well done with clear visual and verbal explanations in proper English. Keep going.
Jean-Claude
Bardzo dobry film, skorzystałem jako instrukcja przy naprawie swojego auta. Do czyszczenia nagaru, a nie mając acetonu, użyłem płynu czyszczącego Meglio, całkiem przypadkiem i również daje świetne efekty rozpuszczając głęboki brud, olej i spieki.
Super dobrze wiedzieć ;) Dzieki i pozdrawiam
Excellent, followed step by step and problem solved. Thank you lads
I'm glad that I helped you ;)
Regards
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.
The car is >8 years old and probably with the mileage to have gone around the world several times. How long warranty do you expect?
@@Mejk4204 that is not the point
@@johnbower The point being?
I fixed the same problem on my 2014 V40 D4 190hp. I had e very hard time cleaning the egr cooler. It was full of carbon deposits.I left it 2 days in different cleaning products and almost no result.Acetone didn't work in my case. After that i used a high presure shower head with hot water and it slowly started to clean up. It took me more than a hour and a lot of dirt was splashing in my face and clotes. Finaly i succeded and i saved about 500 euro. The check engine light is finaly off and the car runs great.
Good to know :) I hope my video helped you.
Regards
Oven cleaner
kobus van boxtel over cleaner is to aggressive to aluminum
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 😵💫
For anyone that doesnt find acetone,i tried with stove cleaner(the one with lye or caustic soda) and it works brilliant.
Yeah I was using Cif Oven and Grill spray to remove old varnish and lacquer from furnitures 😅.
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
Very good tutorial, everything was explained perfectly. Thank you for this video.
You saved me a ton of money. Thanks for sharing your knowledges
Brilliant video!! Two tips, I found I really didn’t need to drain the system, only very little fluids out, and use over cleaner if the cooler is really blocked. Because it’s aluminium don’t leave the oven cleaner on too long, but 15 mins won’t hurt it, and is 100 times more effective than anything else, if the cooler is really blocked, you won’t unblock it with anything else.
I've got some industrial degreaser that will work😂 got the same problem on my s60 I'm going to have a crack at sorting it sunday
Excellent. Many thanks for the very clear to understand procedure.
Keep up the great work.
Had issues with my D4 XC60. Jumping around on cold start. Volvo eventually accepted the EGRs have been an issue. Mine was sticking. They changed it outside of warranty. Kick up a stink. They will change it. It’s a well known issue....
@lewis I just took my car to Volvo Dealer and mentioned this "check Engine" issue. I have the similar error code and Volvo dealer said, there is no recall for this issue from Volvo and Dealer can not fix this issue for free. It would cost me £799 ( labour and parts ). Could you please let me know which dealer did you go to and how did you get this done for free?
@@golamrumi4308 hi. I have a 2016 Diesel Manual Volvo. Within the three year warranty they changed the engine due to the ‘jumping’ on cold start blaming components of the engine. They never needed to do this as in my case the issue was the EGR all along. Basically the cog/lever stuck at points which causes an airflow issue momentarily and as such it jumped. Wasn’t an overly bad thing but for how new the car was at the time , I wasn’t happy. I had no check engine lights or anything like that. I simply argued that this was an issue that arose within the warranty period. They resisted so I suggested I wouldn’t go away. They changed it for free accepting it was the EGR all along. I did my research and read about issues with EGRs. Basically they have been over designed. Cooked far too much and as a result there will be a sludge build up and it won’t go away. Mine had this issue and had the faulty lever. What issue do you have? What are they saying is the issue?
The cheapest option is to program the egr unit and toss it out. Does not damage the engine for the future and if you remove dpf you have a car that will not stomp for a long time and roll smooth er. :)
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???
I did the same thing and it worked, but about two months later, the same problem came back.
You're doing a good job guys (y)
Excellent video, so clearly explained and great tips. 👍👍👍👍👍
The video is very clear. Thank you. Could you please provide the tool list so I can prepare before clean my EGR.
Hello from Finland. Great video. Now I can try it.
I had the same problem with the EGR valve, 90000 KM on my 2012 V60 D3, and the valve is causing problems. The engine light is on, but the engine starts immediately and has no loss of power, but I still have to go to the workshop, in Germany it costs € 600 to repair.
Thank you for your great video! Very helpful. Please let me know what size tool you used. Thank you
I gave the same problem and i am going to use youre procedure.
Only one question, why remove coolant from bottom hose? If i disconnect egr valve not much coolant will escape only from egr ? Egr is on top of the engine!
Perfect thank you 😊 pieknie pokazane jak powinno sie naprawiac samochod brawo
Love the rubbish bag technique 👌
Super good straight forward video! 👍
What an excellent tutorial. Thank you!!! 👋👍👍👍
Thank you for this video, it would be the same kind of process for a v40 d4 2015 my check engine light has came on, I am pretty sure this is the problem the only tools I am missing are the diagnostic
As long as you have the 4 cylinder diesel and not the older 5 cylinder then the process should be as per the video.
@@FatHead1979 yes important to mention its for the 4cylinder D engine , since some 2015 volvo still used the awesome 5cyl... my v40 2015 has a D5204T6
@@erwanfrenchy8849 Lucky you! The older 5 cylinder diesels sound really nice (for a diesel)
Fantastic video, very informative and detailed, thankyou :)
Firstly thank you for uploading this great video and explaining as you went along. About to start this job this week, plus an oil change, would you recommend doing this before the oil change? Thank you in advance
Hi there ;) In my opinion it's better do it before oil change.
Regards :)
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
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.
Thank you very much ,good video , my cooler now is full of acetone hope this is going to work
I left Mine for 72 hours mate. Looks like brand new
nice, understandable movie. One question. Why didn't you drain the coolant from the tap at the bottom of the radiator?
Great tutorial..
Could you help me to clean the PCV valve of this same engine. I have volvo s60 2014, Diesel, 2.0 D4.
Its valve cover gasket is leaking and makes a whistling sound on rpm above 1500. I have tested oil filler cap with rubber gloves, its just inflated and slipped off because of increased pressure. I thought to replace PCV valve but couldn't find it on this engine.
when buying used D4 how to check for such issues or potential issues after buying it ? I understand D5 does not have such issue , correct?
Very good video, can you do one about replace inlet manifold on D4 engine. Thanks
wowowow thanks for this video, perfekt work.
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
Hi,
I'm having trouble with mine as well,
May need to replace it myself as well,
My question is how much did it cost?
As a garage has priced me over £800 for the new egr and that's not including labour
@@sheffcitys2forgedinsteel255 I think mine was around £520 ish. Following this video makes it very easy. I didn’t bother with hose clips either
@@PeterFrench thanks for the reply mate
Don't know whether to try this ( cleaning it )
Or buy a new one and try to fit it myself
@@sheffcitys2forgedinsteel255 I used DIMER cleaner, it got rid of all the crap in it. Worth a go considering the cost garage would charge, even the part itself is expensive. Fitting is fairly straight forward, no special tools required and it took less time that I expected. If you are confident enough with a socket set go for it.
@Peter French yeah i probably will do it myself makes sense and save me probably the best part of a grand if not abit more.
Once again thanks Peter for your insight
Great video, clear to see and excellent instructions
A young mindful mechanic that actually repairs stuff?! Hell am gonna start believing in fairytales again! You mister may work on my cars anytime 👍
subscribed… keep em coming 🤟
Thanks ;)
Regards
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.
Witam
Jakie uszczelki trzeba kupić bo szukam i nie ma kompletu zestawu
Hello
What gaskets do I need to buy if I am going to assemble after cleaning
I broke the handle on the ring of the EGR actuator for the vacuum unit while trying to pry it off. It appears to be just a piece of plastic. Is it important?
I can See that this Car in the Video has the old cooling System. Now in the Year 2020 Volvo Car Corporation has started a new Recall on These engines to solve the Problem with Carbon build Up in the intake manifold
and related parts of the intake System,that effects the EGR System,Cooler and Valve.
Volvo should fix the fault because at the moment customers with cars older then 4 years haven't got help from the dealers
They do if the car is still under warranty AND if you have the car maintained by your official volvo dealer. Otherwise they simply tell you have to buy the parts. don't ask how I know. The problem still comes back anyway. shitty system.
Great video man. I might try it myself also now lol
6:23 You can see 2 "golden" screws to the pipe and EGR module. These have to be unscrewed also.
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.
I've never used it, but it seems like a good idea :)
Thanks for your comment
Regards :)
You didn't show removing the 2 bolts at the rear of the EGR that connect it back into the exhaust system. My Volvo has 2 torx bolts that are near impossible to remove. you can see the connection I am referring to at around 15.02 at the rear of the EGR top center of the screen.
Was wondering the same Peter. They are an absolute nightmare to get access to.
one very big minus is the silicone which is not needed there. you should buy and install new gaskets
OMG this makes me not want to buy a diesel, which I need to have. So many problems 😔
How did you dry the unit after cleaning?
Witam , mam pytanie . W rurce łączącej pokrywę zaworów i odmę z kolektorem dolotowym jak i w samym dolocie zbiera sie olej . Czy to oznacza ze odma już skończyła swój żywot ? Dodam ze zawór egr po kilku miesiącach znowu wymaga czyszczenia i olej trzeba uzupełniać. Pozdrawiam
Great video. Helped a lot to remove and clean the valve and cooler (hardly blocked), but less than a month later "Check engine" light is on again whit the same fault P04D9. Any clue what else can be?
Hi there. Are you sure you cleaned it properly ? I spent more than two days to clean the EGR cooler. Maybe you cleaned it only half way ? After this job it's worth to visit volvo, they have new update for engine ECU. It's changes EGR valve operation.
Regards :)
Very beautiful video well don
I just take it for a fast drive once a month, clears dps , cat and all of that crap. 260 000km still running fine
some work was done on my car by volvo regarding EGR 5 moths ago, since then my cars clock time is wrong and I cant correct it. the sat Nav is also disconnected. when I got the car back it had no coolant fluid in and even after adding the liquid the dash was showing liquid being low.
now my car is showing a ton of fault codes but everything is working right when parts are checked individually.
my XC 60D4 shakes and lacks power to the point it hardly drives.
I would be greatful if anyoe has any advice or experienced the same.
Join to UK volvo v60, xc60 Group or volvo 60 International one mate. Both groups are available on facebook
@@CharlesPiston had same problem with my 2016 volvo V70 D4 Engine. apperently oil been leaking or not burnt correctly and the whole motor is full with oil sludge. and my egr broke. got a new one 1 month later it broke the egr. The car lost power or didnt not accelerate properly either during the .
Many thanks for the tutorial! Where and when I can bring my car to?
Poland mate :)
@@CharlesPiston Gdzie w Polsce?
Suggest. Use high pressure water to clean it
Also advise on buying D4 or D5, for someone who only uses the car for weekends for 1-3 hours...worth buying diesel or gasoline type?
Excellent video. Excellent 👌
What do you think about using a steamer for cleaning the cooler?
That engine still has pretty serious problems.
It consumes oil excessively after 100 thousand kilometres. certainly the used 0w20 oil doesn't help, nor does the mileage of 30,000km for each service. Have you already solved similar problems? meaning did you change the oil with a 5w30 or a 0w30? or are there other problems with this?
excellent video, thanks
Good video and good work, it was very interesting. thanks//////////
Hi, is it possible that it could that also cause a air flow sensor problem ?
Yes,the MAF Sensor is affected.
MAF sensor which is on top of manifold and EMAP pipe which is on the right side, behind the engine
@@CharlesPiston is it possible to remove EMAP pipe for cleaning? Is it easy to remove? Thx.
@@chargrilled9081 I didn't yet but Tom from UK Group did
"you'll need to remove one heatshield, one bolt from the other and bend it away from the banjo to manifold connection. Fiddly but can be done. the pipe is £80 + VAT"
Question, how long after assembling the egr back should you wait until you start the vehicle again for the sealant to cure?
usually that would be stated on the sealant instructions: I would generally expect 24 hours for full curing. Some people on other forums mention the fact that sealant is not actually needed if you use the gasket.
środek do czyszczenia silników mógł pomóc bardziej, również do kominów oraz do piekarników ;) pozdro
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 u need to unplug battery before doing these steps?
Great video, thank you.
Very nice video...👏🏼👏🏼👏🏼
człowiek ledwie zaznajomiony z mechaniką zrobi to krok po kroku czy lepiej oddac do mechanika? pozdrawiam
Cześć, Jeżeli z powodzeniem zmieniałeś kiedykolwiek samodzielnie klocki, to ta robota jest odrobinę trudniejsza i powinieneś sobie z tym poradzić. Jeżeli tego nie robiłeś, lepiej jest oddać auto osobie bardziej doświadczonej.
Pozdrawiam ;)
Hello,
I have fault code P2262, on volvo xc60 2015 2.0 diesel. I have already change 2 sensors but the problem is not gone. Can same one help
tell this customer he needs a cambelt fitting so you can make a video ;-)
:)
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
Hello my Friend.Thank you for the video.I have Volvo 60 XC 2.0 D4(181 2014).Can you tell me the name of your diagnostic programme,please?
Costas.
Hi there it's Autel Maxisys Pro. Regards :)
@@carsguidediy. Siema, można się jakoś z tobą skontaktować przez email. Byłbym wdzięczny
Hi
Do you need to adapt EGR after cleaning?
Very Good job
Witam. Bardzo pomocny tutorial. Czy jestes w stanie określić szacunkowy koszt takiego czyszczenia wykonany przez mechanika? Dzięki i pozdrawiam
Czesc :) Ciężko okreslić dokladny koszt takiej usługi, mechanicy raczej niechetnie podejmują sie czyszczenia. Szacował bym w granicach 600- 800 zl
Pozdrawiam
Witam , a jakie objawy mieliście przy padającym egr i czy czyszczenie pomogło?