D4 engine Inlet manifold and egr system clean

[BB60]

Hi Spaceman.
The jobs all done. I was going to remove and clean the emap pipe at the rear of the engine but the banjo bolt, (14mm from memory) was incredibly tight so I decided to try and use the Vida dice software to monitor. When I can figure out how to.. Help anyone?
With specific regard to the egr and cooler gaskets and seals. I had a real job finding a supplier that actually had stock. I eventually found stock on the autodoc website. I used Elring products and even rang them for info on stock. They were very helpful. I will say that the rear gasket to the egr, (exhaust inlet) is larger than the forward, (exhaust outlet). so it may be worthwhile checking part numbers with Volvo and then doing a search on autodoc.
I did drain the coolant, but only to a level whereby I could work unhindered by coolant. The biggest problem with the cooler is removing and refitting the coolant pipe that sits to the rear of the cooler and is angled towards the passenger side. May I suggest removing the three mounting bolts then remove that particular pipe. I will add that Volvo had previously replaced the egr and coolant back in 2018 and they ommited to refitt the lower most egr attachment bolt.
May I suggest you look at the inlet manifold whilst you're in engineering mode. Remove the TMAP sensor on top of, and to the right on the inlet manifold and shine a bright light in. You should be able to see at least two swirl vanes and any soot/oil deposits. For me this was the biggest shock and I'm convined oil vapour from the crankcase breather is a major factor. Bearing in mind I don't personaly know what was removed by Volvo in order to replace my egr and cooler, I was supprised to find a 20mm deep deposit of soot on the "D" section of the pipe, (that sits inside the throttle body) and that connects the egr output to the throttle body
Other than that it was ok.

[spaceman2844]

Thanks for the detailed and very helpful reply. I'll get the gaskets ordered once I confirm the part numbers. Do you know if there is any particular method required for bleeding the coolant system when refilling?
Cheers.

[BB60]

Spaceman.
Volvo do list a coolant bleed/filler rig. However, I filled the system slowly, (it did gurgle as it filled) went for a short drive, with a container of premixed 50/50 coolant just in case. when I got home I had to put another 500ml in to fill to the max level. I've just driven 12 miles and the level is now constant.
The following two part numbers were applicable to my VEA D4
Please double check them, as they may not be applicable to your Volvo:
EGR to cooler interface gasket. Volvo Pt No 31370267, Elring No 013.630.
EGR exhaust gas output gasket. Volvo Pt No 31370981, Elring No 997.330

I suspect this maybe the EGR exhaust gas input gasket. Volvo Pt No 32213478.

Note that on my engine, the EGR exhaust gas input gasket was larger than the output one.
I hope this helps.

[spaceman2844]

Originally Posted by BB60

Spaceman.
Volvo do list a coolant bleed/filler rig. However, I filled the system slowly, (it did gurgle as it filled) went for a short drive, with a container of premixed 50/50 coolant just in case. when I got home I had to put another 500ml in to fill to the max level. I've just driven 12 miles and the level is now constant.
The following two part numbers were applicable to my VEA D4
Please double check them, as they may not be applicable to your Volvo:
EGR to cooler interface gasket. Volvo Pt No 31370267, Elring No 013.630.
EGR exhaust gas output gasket. Volvo Pt No 31370981, Elring No 997.330

I suspect this maybe the EGR exhaust gas input gasket. Volvo Pt No 32213478.

Note that on my engine, the EGR exhaust gas input gasket was larger than the output one.
I hope this helps.

Excellent info, once again may thanks!

[BB60]

Additional info:
I have just completed the same job exactly, (as mentioned earlier in this post) on a 2015 V40, with a 2.0 litre D4 VEA engine.
Having removed the inlet manifold on two D4 VEA engines now, it is possible to remove the manifold without removing the fuel pipe, (part number 31405314) that runs over the left handside of the manifold, (as viewed from the front of the car looking rearwards). Saving the cost of a replacement fuel pipe.
The amount of oil in the crud mix within the V40, (50K miles) inlet manifold appeared to be greater than the oil level in my XC60, (80K miles). I don't know why this should be, but there we are.
Both engines in my humble opinion had a large amount of oil and soot crud in the inlet manifolds and this is a task I shall be monitoring, with a view to repeating, IF, I retain the car.

[spaceman2844]

Originally Posted by BB60

Spaceman.

The following two part numbers were applicable to my VEA D4
Please double check them, as they may not be applicable to your Volvo:
EGR to cooler interface gasket. Volvo Pt No 31370267, Elring No 013.630.
EGR exhaust gas output gasket. Volvo Pt No 31370981, Elring No 997.330

I suspect this maybe the EGR exhaust gas input gasket. Volvo Pt No 32213478.

Note that on my engine, the EGR exhaust gas input gasket was larger than the output one.

I hope this helps.

I'm assuming from info above that your engine had the input and output gaskets being different sizes (Volvo Pt Nos 31370981 and 32213478). My XC60 is Feb 2014 (MY2014.5). What year is your car? I want to make sure I've got the correct gaskets before I start.

Cheers.

[BB60]

Originally Posted by spaceman2844

I'm assuming from info above that your engine had the input and output gaskets being different sizes (Volvo Pt Nos 31370981 and 32213478). My XC60 is Feb 2014 (MY2014.5). What year is your car? I want to make sure I've got the correct gaskets before I start.

Cheers.

Hi. My Volvo is a XC60 Oct 2014. VEA D4 engine. That said. both vehicles I have done this job on had the same gaskets. Both were 2014, VEA D4 engines.