This is such a great video. I’ve been looking for a video like this forever. My 2004 XC90 D5 has had a bad EGR for a while. Everybody who I take it to wants to do a EGR delete but I want to keep it as OEM as possible. I followed both of your videos and my slow acceleration, hesitating, bad fuel consumption and rough gear shifts have disappeared. At 355,000km it definitely needed a good cleaning. Thanks.
Hello, very helpful video. I'm looking to convert one of these to a water heater. Do you know what I should search to get the plug contact that gives power to the solenoid? 🙏
I’m sure that you would be able to find the connector online - most electrical connectors can be purchased as replacements because corrosion can cause higher than normal resistance and issues with the ECU… search for egr plug wiring socket repair loom or similar - a Volvo dealer would easily be able to source the plug and I bet it wouldn’t be as expensive as you would think. Failing that, any good auto factors should be able to find one for you - thanks for watching!
Thank you for a detailed tutorial, great work! I'm currently in a process of cleaning my egr valve, it's going great so far, however I sheared one of the bolts that attaches valve to the exchanger (the same as the one in your clip 😅). I managed to extract it, but now I need new bolt. Do you possibly know the part number of that busted bolt in your clip?
Many thanks and very glad it helped! The bolt is a fairly standard component - search for “high tensile socket cap screws” or “high tensile Allen head bolts” - you don’t want a hex head bolt due to spanner/socket clearance when you torque it up… there are 2 sizes in the unit - 6mm and 8mm, both standard pitch thread. Thanks for watching!
Check for a blown fuse in the engine compartment… off the top of my head it is something like 11 or 15… I seem to recall that it doesn’t mention the egr valve - should be the one that lists the “solenoid valves and glow plugs” or similar - makes sense if you know that the egr valve is controlled by a solenoid, but a little unhelpful if you aren’t familiar with it’s inner workings!! Thanks for watching!
Ok… run your tester over the output side of the fuse itself to make sure there is power being provided to the cable connector to the solenoid on the egr valve. If there is power at the fuse, that rules out everything except the cable itself… check for cable shorts (typically these will be where it has melted on to the engine block) and/or breaks. If there isn’t power at the fuse, check the main fuses that feed the lower fuse - though if that were the case I’d expect other things to not work - your glow plugs for instance. Final thought would be to look for any evidence of an unofficial “egr delete” having been done on the vehicle… I can’t give you any clues on that unfortunately as there are number of ways to do that particular hack job… hopefully it isn’t that!
@@bigtalltim Hello, with respect again. I have another problem, I took off all the vacuum hoses, and now I don't know how to mount them. Do you have a diagram? Thank you very much
Probably would of been better if you didn't use your impact gun. You had me cringing when you was doing it. Apart from that nice explanation and a great clean up job.. 👍🏿
A fair point, but the danger with trying to remove the bolts manually is that with sustained torque they can twist out and snap... the impact gun doesn't apply such sustained force as it comes in a series of violent jabs. Check out the bolt removal video for an example of exactly that - the last one of these that I restored snapped on me! Never had a problem since using the impact. Thanks for watching :)
This is such a great video. I’ve been looking for a video like this forever. My 2004 XC90 D5 has had a bad EGR for a while. Everybody who I take it to wants to do a EGR delete but I want to keep it as OEM as possible. I followed both of your videos and my slow acceleration, hesitating, bad fuel consumption and rough gear shifts have disappeared. At 355,000km it definitely needed a good cleaning. Thanks.
You are very welcome - glad it worked out for you, and thanks for watching!
Nice and interesting video. I'd recommand new metal gaskets as they are not intended to be used twice.
A fair point, but I haven’t managed to find a source… a little exhaust paste will help if you have to reuse one
Hello, very helpful video.
I'm looking to convert one of these to a water heater.
Do you know what I should search to get the plug contact that gives power to the solenoid? 🙏
I’m sure that you would be able to find the connector online - most electrical connectors can be purchased as replacements because corrosion can cause higher than normal resistance and issues with the ECU… search for egr plug wiring socket repair loom or similar - a Volvo dealer would easily be able to source the plug and I bet it wouldn’t be as expensive as you would think. Failing that, any good auto factors should be able to find one for you - thanks for watching!
Thank you for a detailed tutorial, great work! I'm currently in a process of cleaning my egr valve, it's going great so far, however I sheared one of the bolts that attaches valve to the exchanger (the same as the one in your clip 😅). I managed to extract it, but now I need new bolt. Do you possibly know the part number of that busted bolt in your clip?
Many thanks and very glad it helped! The bolt is a fairly standard component - search for “high tensile socket cap screws” or “high tensile Allen head bolts” - you don’t want a hex head bolt due to spanner/socket clearance when you torque it up… there are 2 sizes in the unit - 6mm and 8mm, both standard pitch thread. Thanks for watching!
I have an S60 D5 from 2003 and I have no voltage on the wires going into the egr
Check for a blown fuse in the engine compartment… off the top of my head it is something like 11 or 15… I seem to recall that it doesn’t mention the egr valve - should be the one that lists the “solenoid valves and glow plugs” or similar - makes sense if you know that the egr valve is controlled by a solenoid, but a little unhelpful if you aren’t familiar with it’s inner workings!! Thanks for watching!
@@bigtalltim unfortunately I checked the fuses and they are good. Any other ideas?
Ok… run your tester over the output side of the fuse itself to make sure there is power being provided to the cable connector to the solenoid on the egr valve. If there is power at the fuse, that rules out everything except the cable itself… check for cable shorts (typically these will be where it has melted on to the engine block) and/or breaks. If there isn’t power at the fuse, check the main fuses that feed the lower fuse - though if that were the case I’d expect other things to not work - your glow plugs for instance. Final thought would be to look for any evidence of an unofficial “egr delete” having been done on the vehicle… I can’t give you any clues on that unfortunately as there are number of ways to do that particular hack job… hopefully it isn’t that!
@@bigtalltim Hello, with respect again. I have another problem, I took off all the vacuum hoses, and now I don't know how to mount them. Do you have a diagram? Thank you very much
Hi - do a google search for “s60 2.4 d5 euro 4 2006 vacuum diagram” and go to the link at volvoforums.org.uk
Does it fix limp mode error, with bad emmisions?
Great question! If the limp mode (most often with the “engine service required” message) is because the egr valve has got stuck, definitely yes!
Tnx, cleaned all, mine was not so dirty. Cleanded all electric connections, with contact cleaner and now works perfectly. 😉👍 Did clean muf sensor too.
@opis1188 awesome! Glad it worked for you - and thanks for letting us know!
Probably would of been better if you didn't use your impact gun. You had me cringing when you was doing it.
Apart from that nice explanation and a great clean up job.. 👍🏿
A fair point, but the danger with trying to remove the bolts manually is that with sustained torque they can twist out and snap... the impact gun doesn't apply such sustained force as it comes in a series of violent jabs. Check out the bolt removal video for an example of exactly that - the last one of these that I restored snapped on me! Never had a problem since using the impact. Thanks for watching :)