S80: Engine Help with 185hp d5 egr removal.

[Vol S80 Lux]

Hello

Iv been told my trusty mechanic that I need to clean the egr valve on my s80 2.4 d5.

Iv located it, removed the necessary pipework and removed the 2 10mm bolts at the top but I cant find any more bolts presumably underneath the egr.

Is the a 'how to' for this or any advice for where I need to look to remove the egr?

Thanks in advance.

[Vol S80 Lux]

My vin is YV1AS714171005896 if that helps.

Hope it does

[tt82]

The EGR valve bolts to the EGR cooler from the cooler side. This means the bolts are hidden underneath the high pressure fuel pump. When I cleaned mine, it was a case of removing the pipes to the EGR valve on both sides, remove the undertray, cover the engine/radiators with a bin bag and do the best job you can, allowing the gunk to fall down in between the bags to the floor underneath.

[Vol S80 Lux]

Originally Posted by tt82

The EGR valve bolts to the EGR cooler from the cooler side. This means the bolts are hidden underneath the high pressure fuel pump. When I cleaned mine, it was a case of removing the pipes to the EGR valve on both sides, remove the undertray, cover the engine/radiators with a bin bag and do the best job you can, allowing the gunk to fall down in between the bags to the floor underneath.

So it looks like a cooler pipe removal job. I think thats a bit too much for me. Might have to let the mechanic have a go.
I have seen a few pics and vids of this online. I was hoping i could avoid that.

[Dancake]

The cooler will be full of soot and carbon as well, so removing only the valve for cleaning would be a pointless exercise if it was possible. All you have to do is clamp the top coolant hose to prevent the block from draining, then remove the hoses from the cooler as well as the three screws holding the cooler and valve to the engine block. There really isn't much to it. The Euro 4 EGR is a bit more complicated than the Euro 3 equivalent, but if you have time and patience it's well within the remit of a diy mechanic.

[tt82]

Indeed the cooler will be full of soot as well, I have a suspicion that eventually this soot will block it up as the pipes through the cooler are only narrow and the issue will resolve itself. As to whether there is merit to only cleaning the valve and not the cooler as well? Well the intake manifold will also be full of soot but removing this is a bit more complex and if you follow Volvo's instructions about using new injectors seals - £40 per injector- also quite expensive!

I have added a picture of a D5 engine with the associated EGR Valve/Cooler, would it be possible for you to show us where the bolts for the cooler are, as I've not been able to see them previously.

[Vol S80 Lux]

Iv just spent a few minutes to follow the cooler pipe but i cant locate any screws/bolts for it. The battery cage gets in the way which might need removing.

Is there any clear info/diagram out there I could use to find out how to go about the egr and cooler pipe removal?

[tommyweaves]

If you have an early P3 D5 185 then isn't it the same engine as the late P2 D5 185?

If that's the case then have a look on that forum.

[Vol S80 Lux]

Originally Posted by tommyweaves

If you have an early P3 D5 185 then isn't it the same engine as the late P2 D5 185?

If that's the case then have a look on that forum.

What Iv done is left the egr bolted on the car and removed the pipework from both ends and cleaned all the way through. Its still not any better. Thats what Iv found on other forums too. The car is still sluggish in lower gears/revs and the smell of diesel is still there when I put the heaters on.

At least Iv had a go. Must let the mechanic try now. But I will be watching him. Might takes some pics as well.

[Vol S80 Lux]

Update.

I didnt go to the mechanic. Instead I took the four 8mm bolts on the end if the egr off and removed the butterfly on the air filter side. Not sure what the exact name for it is. With that out of the way, the view was much better, and so I realised the egr was still coked up. I spent a good 2hours cleaning the egr. I used petrol to clean the black right angled pipe that connects the egr to the top side of the engine and an old toothbrush and rag.

Result; all is well. The power delivery/throttle response is brilliant again and the smell of diesel from the air vents has gone too. Really pleased to see 40 pounds in my pocket and the car back to how it used to be. Havent done anything with the cooler pipe but I assume it wasnt too bad anyway.