Volvo 2.4 Diesel EGR & Intake Manifold Removal/Cleaning (D3, D4, D5)

In this video, we demonstrate the procedure for removing and cleaning the EGR and intake manifold (valve cover) of all Euro 5, 5-cylinder diesel engines badged under D3, D4, D5, and D6 variants. Unlike the newer 2.0 VEA generation, the 2.4 Euro 4/Euro 5 are not as susceptible to carbon buildup, however, regular cleaning and inspection are still necessary to ensure smooth operation over time. This procedure is compatible with all models equipped with this engine, including the V60/S60/S80/XC60/XC90/C70.
Website link:
www.gsautomods.com/volvo-soft...
Social media link:
profile.php?...
Video chapters:
0:00 Introduction
2:08 Injectors removal
5:28 EGR removal preparation
8:12 Coolant draining
10:34 EGR removal
16:09 EGR assembly
24:58 Intake manifold removal
30:14 Valves cleaning
33:03 Injectors assembly
35:38 Engine start
Part numbers:
30777600 - intake manifold gasket;
30757766 - throttle gasket;
30774580 - EGR cooler to cooler valve gasket;
31219276 - cooler valve to EGR gasket
31272771 - injectors o-rings (2x);
31216247 - injector copper gasket
987494 - injector clamp bolts
31303973 - injector clamp

[@IronFlame5]

Finally a movie instruction how to do it properly on the D3 2.0 engines. Thank you so much!!!

[@laszlovona]

OMG this video did not even "exist" when I decided to do this on my V60. I did it by VIDA and yes . the small exhaust pipe at the back of.the cooler is a btch... 😢.. thank you for this excellent tutorial!! I have yet to to the intake ... I am a bit freaked out removing injectors..

[@Gryzli22]

Fantastic movie. Great job. This is waiting for me too, but I'm having trouble finding a workshop that will do it carefully and correctly. Greetings from Poland ❤❤❤

[@tfaccountant]

Thank you for the video, Georgi!

[@powerkhe]

no nees extractor of injector

[@aldobarr9820]

Super interesting, thank you very much for your video ! One question, how man kils has this Volvo ? Thank you :)

[@aldobarr9820]

One more question : is it possible to clean the EGR without removing everything as you explained ? - thanks again

[@GSAuto681]

@aldobarr9820 Hi, just the valve could be cleaned by removing the charge pipe on the throttle body side. To fully clean it with the cooler, it will have to be dismounted. Rgds.

[@sheffcitys2forgedinsteel255]

Great job,
But it's not the same process on a Volvo D4 2.0 the EGR and cooler are completely different nowhere near the same

[@juleshere5201]

Never use silicone where you need to replace o-rings. The rubber o-rings should suffice.