S40 (New) General : EGR Valve Engine Plug/Socket Location On 2010 1.6D Volvo S40

[ancuisle]

Hi There,

I just bought a replacement EGR valve for my 2010 1.6D Volvo S40.

I need to know the location of the socket/plug for the grey plug on the end of the EGR valve wire loom that plugs into the engine?

The replacement EGR valve came with wiring loom attached which does not unplug from top of the EGR valve.

See image attached.

Any pointers would be greatly appreciated!

Thanks!

[iainmd]

Doesn't look like a compatible valve to me. I'd warn against using non-OEM Volvo EGR valves as they often play up.

[ancuisle]

Bought on ebay: https://www.ebay.ie/itm/253003735485 it says it is compatible with s40?

[iainmd]

Like I say, non-Volvo EGRs are best avoided. I say that from experience. At the very least, if the connector on what you've been supplied doesn't marry up to your car then it's fair to say it's not compatible.

I'd recommend returning it and getting a genuine Volvo EGR. It will cost more but you're assured it'll work.

[ancuisle]

I don't know where the connector plugs into to check if it is compatible or not? Do you know the location of the socket/plug for the grey plug on the end of the EGR valve wire loom that plugs into the engine?

Thanks for the reply!

[TheMenace]

It looks like the one you bought has come with a fly lead to adapt it to the other cars that came with the same engine. If you can, remove the lead from the new EGR and see if the wiring loom in your car fits the plug in the top of the new EGR.

This is how my ebay EGR looks (2010 1.6D):


But like others said, go genuine, I'm planning to replace mine next service. Some dealers give a discount to VOC members which could save you some as they aren't cheap.

[ancuisle]

Thanks for the reply!

The lead on the new egr appears to be fused on or molded as one unit, it is definitely unremovable which is why I can only plug the grey plug at the end of the wiring in to the socket on the engine(assuming there is one).

I have bought a blanking plate from Amazon and will try this with the old egr valve.

The annoying thing is the car was starting/driving fine but was showing fault codes on a scanner so I took it out and cleaned it, put it back in and it now cuts out after briefly starting and will not rev above 3000rpms....should have left well enough alone!!

[TheMenace]

A blanking plate won't help at all - sorry! It'll only start throwing more codes.

What code reader are you using?
It does sounds like EGR problems, but you need VIDA to know for sure, and need VIDA to code in a new EGR when you install it - a universal code reader won't do this. You'll also need it to reliably pull it out of limp mode (which is why it's being held below 3k revs).

As a last resort, you could try carefully removing the four screws off the top of your old EGR and seeing if the motor inside is moving freely.

[ancuisle]

This is the reader I use with the Torque app: https://www.amazon.co.uk/gp/product/...?ie=UTF8&psc=1

Car Scanner ELM OBD2
DTC report
Selected brand: Volvo

============1==============
P0490
Raw code: 0490
ECU: 10
Status: Pending fault present, Pending fault present during this driving cycle, Test conditions are met, Test is inhibited by other DTC, Test has not been completed, Validated and stored in non volatile memory, Validated fault present at time of request, Validated fault has been present during this drive cycle
OBDII: Exhaust gas recirculation (EGR) system - circuit high

============2==============
P0401
Raw code: 0401
ECU: 10
Status: Pending fault present, Pending fault present during this driving cycle, Test conditions are met, Test is inhibited by other DTC, Test has not been completed, Validated and stored in non volatile memory, Validated fault present at time of request, Validated fault has been present during this drive cycle
OBDII: Exhaust gas recirculation (EGR) system - insufficient flow detected

============3==============
P042F
Raw code: 042F
ECU: 10
Status: Pending fault present, Pending fault present during this driving cycle, Test conditions are met, Test is inhibited by other DTC, Test has not been completed, Validated and stored in non volatile memory, Validated fault present at time of request, Validated fault has been present during this drive cycle
OBDII: Exhaust gas recirculation (EGR) valve actuator A - actuator stuck closed

I did take off the electrical cover from the old egr and the motor seems to be turning freely.

What gets me is how could it stop working by just taking it out cleaning it and replacing it?

Thanks!

[iainmd]

As posted before, there's a really simple way to fix this. Send the incompatible one back and buy a genuine EGR valve.

Blanking it is likely to throw more errors and is (in the UK anyway) an MOT fail.

Beware that whatever one gets fitted you need to recalibrate the EGR using Volvo's VIDA/DICE. Torque won't help you with that. Some more expensive generic diagnostic systems can but find someone with VIDA to do it and it'll be easier.

In answer to your last question, mine was similar. I took it off, cleaned it with EGR cleaner, and it became worse than before even with VIDA recalibration afterwards. I replaced it with a Haas aftermarket one from Euro Car Parts and the errors persisted. Finally, replaced with a genuine one from Volvo and all was back to being fine again with no errors.