Help please for a 97 V40 1.9 TID

[DeeVee]

Good afternoon Volvo people, both boys and girls!
This is my first post on here so please be gentle with me.
I will confess to being a Saab driver/owner but at least it's Swedish so don't shout!
The reason I have joined is to help out my father in law.
He has a 1997 'R' reg. V40 1.9 Tid estate which he has had from new and it only has 52K miles on the clock.
He is having running problems with it at the moment, where by, when it's warm it is blowing an awful lot of grey smoke out and it also has rise and falls of engine revs as well.
I read with great interest and photo help also, the article about cleaning the EGR valve and throttle body by 'BioToxic', so I thought that's what I'll do - as I have cleaned the EGR on my 2.2 Tid Saab a few times.
Been down this morning, but when I took the black plastic engine cover off, it didn't quite resemble what 'BioToxic's pictures showed.
The intercooler hose didn't come from the front of the car, but down the the right hand side (as you are looking from under the bonnet).
What bothered me more, was that at the inlet manifold chamber there didn't appear to be a EGR valve housing.
So my questions are:
Does this have an EGR, and, if so, where is it?
Any tips or hints as to what to investigate and look for in helping him out.
Apparently a local garage had his Turbo rebuilt but the issue is still the same - not sure how they came to that conclusion!!
Could there be a split hose somewhere, if so, which one is the usual culprit?
What will need cleaning out of soot etc?
I tried to pull any DTC's from the ECU but my cheap E-Bay scan tool kept failing with a 'Link Error'
One other thing, which seems bizare to me is that when the ignition is one, there is quite a loud electronic clicking noise from under the driver's footwell, a bit like a 'sticking' solenoid, but when it starts, the noise is still there??
I look forward to reading all your replies.
Many thanks
DeeVee

[v40alex]

The EGR is at the back of the engine (bulkhead end) on the right hand side as you're looking in from the front. Follow the big black tube off the airbox and it's above that. It's a little bit hidden underneath the shutoff valve - take that off first and the EGR is easier to get to. Still can be difficult to get off, prepare for lots of swearing. If you still can't find, I can post the service manual picture.

White smoke is unburnt fuel or moisture - try cleaning the EGR first but could also possibly be dodgy injectors or head gasket failure (does the coolant level need topping up regularly?).

1.9D is very fussy about code readers, try a local specialist (not the one that rebuilt the turbo ) or main dealer, or track someone down on the forum with a compatible one http://www.volvoforums.org.uk/showthread.php?t=136759

Clicking in the driver footwell could well be a relay in the CEM, are the headlights/full beams ok?

[DeeVee]

HI V40Alex,
Many thanks for your reply. I think I know where it is but if you could post a picture that would be excellent.
Is this EGR serviceable in the sense does it get gunged up like the others and can it be cleaned just as easily?
I'll check on the headlights next time I'm helping him out.
Look forward to seeing the picture.
Thanks again

Dave

[v40alex]

Hi Dave,

Ignore what I first said - you have a different engine from me . Your EGR valve is on the inlet manifold, exploded diagram attached (it's part 1). I believe it is cleanable, the later models certainly are, they all do the same sort of job so good chance it's coked up if the car hasn't done many long runs. Volvo did do a replacement EGR at one point, but not sure which engine that applied to, so the one in the pic may look a bit different to yours if it's been upgraded. Hope this helps...

[DeeVee]

Alex,
Many thanks for that, that is the one.
I have established that the engine in his car is the D4192T 90hp engine.
Excuse my ignorance, but in your original reply regarding the 'clicking' noise, what is 'CEM'?
I will report back on how I'm getting on.
Thanks again, very much appreciated.
Regards

DeeVee

[v40alex]

The CEM is the Central Electronic Module - one of the car's brains . Come over to the V40 section, have a look at this thread http://www.volvoforums.org.uk/showthread.php?t=67584. I've only had 95 and 115hp versions, not entirely sure if it will be in the same place but pretty sure it is. If not, I can look it up. There are some other relays for the rear wipers etc in a fuse box under the dash too on the earlier models, you need to get an exact location of the clicking noise but my hunch would be a relay.

[skyship007]

First things first, so a few questions:

1/ Is the engine burning oil or is the grey smoke steam?

2/ Is the coolant level dropping?

3/ When was the engine last serviced?

4/ Does is start instantly?

5/ Have you seen the low oil pressure light flicker at hot idle?

6/ Does it rattle more when hot than cold?

7/ What is the temp gauge doing when hot (It should be 12 O'clock only)?

8/ Is there an oil leak from the turbo area?

I would not be too concerned about the EGR at the moment, as it's unlikely to block in 52K miles and the symptoms don't seem similar.

Getting the codes read would be a good move and if it's rattling badly at hot idle, I would not run the engine again until you confirm something serious, like petrol in the diesel tank is not involved.

No real idea what this might be, as it could be something silly like a birds nest in the intake or petrol in the tank, BUT it might also be head gasket trouble or blown turbo sucking oil in.

If this diesel was not run every month, then even though it only has 52K, the injector tips could have corroded, or an oil control ring stuck etc.

[Baffler]

Originally Posted by DeeVee

He is having running problems with it at the moment, where by, when it's warm it is blowing an awful lot of grey smoke out and it also has rise and falls of engine revs as well.

1.) Is the smoke definitely grey?

2.) If so...when was the cam belt last replaced? Possible injection pump timing.

3.) Are there any oil deposits in the coolant expansion tank/bottle? And/or, as per Skyships question, is the coolant level dropping?

Originally Posted by DeeVee

One other thing, which seems bizare to me is that when the ignition is one, there is quite a loud electronic clicking noise from under the driver's footwell, a bit like a 'sticking' solenoid, but when it starts, the noise is still there?

Is this not the seat belt warning relay?


The EGR valve on the D4192T and D4192T2 is attached to both the inlet and exhaust manifolds and is vacuum operated via a solenoid valve on the bulkhead. Top left in the pic:

[DeeVee]

Guys, apologies for the delay in posting a reply, but thanks for all your input.

V40Alex and Baffler, how embarrassing, but Baffler wins the prize......the clicking noise was indeed the seat belt warning. That's the easy one out of the way.

Apparently a local garage has fitted a new head gasket and had the turbo rebuilt. The output from the exhaust, is not steam but an oily greyish smoke.
The father in law says that it is losing a little water but also says that the oil level is ABOVE the max on the dipstick, which I don't believe is a good thing.

I'll have to find out and report back as to when it was last serviced and the cam belt replaced.

It does start quite easily, no real delays.

I managed to take off the EGR valve on Friday and it really was fine, not what I was expecting, but I do think it has been off before, because one of the 2 allen headed bolts that hold the top of it to the inlet manifold, had been cross threaded - which I assure you I didn't do - so it is not fully tight.

As regards the revs hunting when it is warm, what hoses could be causing that if split? The turbo inlet trunking looked fine when I examined it.

I really do appreciate ALL your input, it is most helpful but I will be back with
more replys when I get to see the car again and speak to my father in law.

Top guys indeed

[v40alex]

Originally Posted by DeeVee

the clicking noise was indeed the seat belt warning

When I saw what Liam had wrote I had one of those realisation moments, glad it was an easy fix

Drain out 1 litre of oil and it will be somewhere in between the marks (2litre range between min and max). Sump plug is an 8mm square bit, just discovered you can unscrew it with a door handle insert if you don't have the bit.

Loosing coolant is a bit worrying, I would monitor that carefully. On the bright side it might just be airlocks working their way around if it was done recently. Also check the jubilee clips on the lower radiator hoses, they corrode.

Revs hunting could be lots of things. With the oil being above max, has the level risen on its own or was it overfilled? You should get the codes read really.