D4 VEA 'check engine' light / EGR fault thread

[Zebster]

Originally Posted by Miyo360

A year later (almost to the day) since I last experienced this, and I have just taken my XC60 into the local dealer to investigate the EML warning light.

Dealer just called... "the EGR cooler is blocked" and they are contacting Volvo UK for a goodwill gesture. I hope it's 100%!

In my March 2019 post on this topic, I mentioned the dealer had told me about the latest design being teflon coated, but barely 6000 miles later it has gone again.

When I get the car back, I think it's time to sell up.

That doesn't bode well! Can't blame you for wanting to sell up.

I'm on my second replacement cooler. But I've also had a replacement EGR valve and very recently an intake manifold.

[Zebster]

Originally Posted by Discombobulated

A quick update on our V60, the dealer called today to arrange a new inlet manifold and EGR cooler, Volvo are covering it all as recall and goodwill.

Our car is a 64 reg D4 with 53,000 miles. It had its first three services at Volvo and when we bought it it had just had its fourth at the independent dealer we bought it from so we took it to our local dealer for an oil and filter change and then had it serviced there last year so it’s got a pretty much full dealer history, the dealer said were more likely to get goodwill if it has.

It’s going in on Thursday for the work even though the dealership will be closed, apparently because it’s a safety issue they won’t leave it for three weeks.
They don’t have any hire cars but I suppose we can’t really moan considering all that is happening in the world right now.

I know these VEA engines have got quite a bad name because of these issues but I have been impressed with Volvo and the dealership. I’m not sure how old these cars will be before Volvo stop contributing goodwill but for now I’m happy.

I won’t be there when the car goes in but I’ll try and find out what the issue is with this redesigned inlet manifold that was fitted last year.

Having just had a replacement intake manifold fitted to mine (due to the swirl valves found to be sticking when it was removed during an intake valve leak test) I'm really interested in why your replacement manifold failed!

Manifold was 100% goodwill but the EGR valve last year was only 50% goodwill.

[Discombobulated]

Originally Posted by Zebster

Having just had a replacement intake manifold fitted to mine (due to the swirl valves found to be sticking when it was removed during an intake valve leak test) I'm really interested in why your replacement manifold failed!

Manifold was 100% goodwill but the EGR valve last year was only 50% goodwill.

Out of interest what is the cost of an EGR valve or cooler if Volvo weren’t contributing?

I’ll try and keep you posted

Cheers, Luke

[Zebster]

Originally Posted by Discombobulated

Out of interest what is the cost of an EGR valve or cooler if Volvo weren’t contributing?

I’ll try and keep you posted

Cheers, Luke

Total parts and labour plus VAT for cooler and valve replacement combined was about £1500. When investigating the stuck valve the dealer also discovered that the cooler was again almost blocked (valve and cooler have to be removed together then separated) so were granted 100% goodwill on the cooler and fortunately all the labour cost for both was put against the cooler replacement. However the valve alone was an expensive part and so even with 50% goodwill on that it still cost me £337.

If Volvo weren't contributing then I'd do it myself... https://www.youtube.com/watch?v=5zz6...index=3&t=922s

[Discombobulated]

We have had the inlet manifold and EGR cooler replaced, dealership said the inlet manifold has been replaced with an identical one, the problem was with the heat caused, but after this recall for a software update the temperatures will be lower (somehow) so it shouldn’t keep happening.

I asked the service manager what he thought of these engines and he said he’s worked at the dealership for 38 years, he has a company car at present but when he retires in a couple of years he honestly wants an S60 or V60 D4. I asked how long he thinks it will be before Volvo washes their hands of these problems and he said they won’t.

I guess time will tell.

Cheers, Luke.

[Zebster]

Originally Posted by Discombobulated

We have had the inlet manifold and EGR cooler replaced, dealership said the inlet manifold has been replaced with an identical one, the problem was with the heat caused, but after this recall for a software update the temperatures will be lower (somehow) so it shouldn’t keep happening.

I asked the service manager what he thought of these engines and he said he’s worked at the dealership for 38 years, he has a company car at present but when he retires in a couple of years he honestly wants an S60 or V60 D4. I asked how long he thinks it will be before Volvo washes their hands of these problems and he said they won’t.

I guess time will tell.

Cheers, Luke.

I'm sure the slightly later VEA diesels with AdBlue have far less problems, due to the much reduced EGR flow.

I have to say that mine is a nice car to drive... responsive, adequate power wherever you are in the rev range and good mpg. It's just the soot-related worries that ruin it a little for me.

[Miyo360]

Originally Posted by Miyo360

A year later (almost to the day) since I last experienced this, and I have just taken my XC60 into the local dealer to investigate the EML warning light.

Dealer just called... "the EGR cooler is blocked" and they are contacting Volvo UK for a goodwill gesture. I hope it's 100%!

In my March 2019 post on this topic, I mentioned the dealer had told me about the latest design being teflon coated, but barely 6000 miles later it has gone again.

When I get the car back, I think it's time to sell up.

...UPDATE: So the garage (MKG 3000 of Twickenham/Strawberry Hill, London) submitted an automated request for contribution, which they say came back with a low offer. So they submitted an "exceptional goodwill gesture" request, which was reviewed by a person and agreed to cover 100% of the costs. Fantastic service by MKG!

When collecting the car, I asked if the design of the cooler had changed in the last year and the guy said not. But that the "mapping" had been updated or something. Not sure what that means. I'm just happy my '64 car with 123,000 on the clock is still getting free fixes for this. Good luck to all.

[Longweekend]

Great result....

[Discombobulated]

Originally Posted by Miyo360

...UPDATE: So the garage (MKG 3000 of Twickenham/Strawberry Hill, London) submitted an automated request for contribution, which they say came back with a low offer. So they submitted an "exceptional goodwill gesture" request, which was reviewed by a person and agreed to cover 100% of the costs. Fantastic service by MKG!

When collecting the car, I asked if the design of the cooler had changed in the last year and the guy said not. But that the "mapping" had been updated or something. Not sure what that means. I'm just happy my '64 car with 123,000 on the clock is still getting free fixes for this. Good luck to all.

A technician at our dealer said the coolers have been modified with larger ports for the gasses to pass through to stop them blocking up. I asked if it would stop them clogging up or just take longer for them to, at which point he walked away without comment.

Cheers, Luke.

[Zebster]

Originally Posted by Discombobulated

A technician at our dealer said the coolers have been modified with larger ports for the gasses to pass through to stop them blocking up. I asked if it would stop them clogging up or just take longer for them to, at which point he walked away without comment.

Cheers, Luke.

Or maybe the soot will now more freely pass through the cooler and so lead to the intake manifold/swirl valves/intake valves being more likely to become clogged?