D4 2.0 possible cracked block
 

recently had my car in for the EGR cooler cleaning out as was recommended by my local garage, on picking the car up I noticed there was a gurgling noise (coolant) I could hear when I stopped a lights or a junction. I presumed this was air and would force its way out through the expansion tank. days later I pulled out of the drive and the car lost power and had white smoke from the exhaust. the guy from the garage came out and has said I now need another engine as he thinks the block is cracked, obviously not admitting to anything he's done but to me its too much of a coincidence as never having any issues before the garage visit. could it just be the cooler failing? or is it more likely to be head gasket or cracked block? or have I just been unlucky as the car has covered 150k miles. I believe it has something to do with something the garage has done but obviously cant prove anything.
also would you have to take the inlet manifold off to clean the cooler, as I noticed he`d taken it off when I called in to see if the car was ready.

He thinks that the block is cracked ... what led him to that conclusion?

Cracked blocks are (thankfully) quite rare and are usually caused through frost damage due to little or no antifreeze.

The symptoms that you describe are much more likely to be due to HG failure in my view. I'd check for that first in the usual way before worrying about the block. If it is the block, I'd look for a good secondhand engine as a replacement, since block repairs can be difficult and may not always be successful.

Regards, John.

Did the garage drain the water to clean the EGR cooler? If so, did they put any water back in or top up correctly ??!!

The white smoke suggests that water is indeed getting into the engine , however to clean the egr valve the unit has to be split and then resealed I would be suspecting the join between cooler and egr valve is leaking and allowing water to get into the egr valve and then it's getting drawn into the engine .

that's all the information I can give at the moment, I have it booked in at another Volvo specialist but that's not for another 2 weeks. hopeful not an engine replacement.

Assuming this is the 2014 and later 2.0 4 cylinder VEA......

It is ESSENTIAL that the cooling system on this engine is Vacuum filled, a tool to evacuate all the air MUST be used and then the coolant is drawn in leaving no air whatsoever in the block or head or pipes of which there are many.
If this local garage has not done that there will be air locks and local boiling in the engine which may have damaged it. That's why dealers charge what they do for the Knowledge and these special tools they have to buy..
Also if the car is pre 2017 they should fit a new EGR cooler as it is an improved one with larger channels.
I would get it filled properly by someone who knows what he is doing and see how it goes...Although steam out the exhaust is bad..
I would go to the garage and ask to see there and then the vacuum tool they used to refill the coolant on your previously good engine.👍

No need to remove the inlet manifold to access the cooler. You just need to move the vacuum tank to one side which allows access to the cooler screws.

I wonder if a corrosive chemical was used in the cooler to speed up the process?

It's Stainless steel

For all we know they could have use a plasma cutter to clean it 😆 🙁

Just thought I would mention it as I've seen VAG EGR coolers let go in spectacular fashion and would explain the steam from the exhaust the OP has experienced.

yes its the 2.0 d4 VEA. this was done by my local volvo specialist, i cant belive they didnt know this.