S80: Engine Help with 185hp d5 egr removal.

[Rooster]

The coolers are usually fine on the 185 engines as they don't come into contact with any air flow from the intake side of the engine like the earlier euro 3 engines do with the egr been at the front rather than the rear of the engine.

The 185 engine egr valves are a pig to remove (worse if its and auto) and best cleaned in place which is also abit awkward but alot easier than trying to remove.

[tt82]

I was talking with a lad who has a V50 D5 manual on Sunday, he spent 16 hours taking the car apart to clean the EGR. To get it off, you have to take the airbox and battery out which gives you access to the cooler, as well as some of the high pressure fuel pipes. You can then get to the bolts for the cooler and remove that. You'll need to remove the pipes for the engine coolant which means you'll lose some, may be worth putting new coolant in.

We did both agree that the intake manifold would also require cleaning, apparently you can get new seals off ebay for £5, making it a lot cheaper than buying Volvo seals.

[NorthantsPete]

Originally Posted by Rooster

The coolers are usually fine on the 185 engines as they don't come into contact with any air flow from the intake side of the engine like the earlier euro 3 engines do with the egr been at the front rather than the rear of the engine.

The 185 engine egr valves are a pig to remove (worse if its and auto) and best cleaned in place which is also abit awkward but alot easier than trying to remove.

long term bump... but do you have any info on that?
I think id like to clean mine but i also want to keep it simple and use some egr sprays, clothes, etc.

[Semnoz]

Originally Posted by NorthantsPete

long term bump... but do you have any info on that?
I think id like to clean mine but i also want to keep it simple and use some egr sprays, clothes, etc.

Overall, it is possible to remove both the large hoses on the LHS and RHS of the EGR valve body, and clean it in situ.

Remove hose from top cover. If yours has a rubber outer joining sleeve, undo the hose-clips so that you can slide this sleeve fully out the way. The top hose is not very flexible so can't easily be pushed out the way. You might end up thinking it's easier to remove the engine top cover, but this isn't recommended. Remove the airbox and then the hose feeding the RHS of the EGR valve.

My approach was to secure a plastic bag around the RHS of the valve body, spray loads of carb cleaner into the LHS and scrape the gunge out, pushing it through into the bag. I also prodded scrunched up balls of kitchen towel through from the LHS, and out into the bag.

Bear in mind, if the EGR valve is really clogged up, there's a chance the entire inlet hose/manifold (top cover) also needs cleaning.

Some info here:
https://www.volvoforums.org.uk/showthread.php?p=2345373

[Vol S80 Lux]

Originally Posted by NorthantsPete

long term bump... but do you have any info on that?
I think id like to clean mine but i also want to keep it simple and use some egr sprays, clothes, etc.

Use brake cleaner spray to clean the coke.
Iv been told it works brilliantly.

[NorthantsPete]

thanks ive got carb cleaner but ill try brake cleaner too if its not shifting

[bobsy852]

So im in the middle of removing my EGR due to a suspected failed motor in the unit (had it diagnosed 3 times now and tried to clean the EGR as above to no avail).

Anyway i have everything undone on the EGR & cooler all the coolant hoses etc.
Only thing im struggling with is how to undo the exhaust flexi pipe at the back of the cooler?ive undone the jubilee clip but it wont budge. Anyone got any tips?

Thanks in advance. Rob