S/V40 1.9D Shut-off throttle & EGR valve

[pphilpot]

This is a great post, thanks Baffler. When I tried to do my EGR a few weeks ago, it was stuck solid in the inlet manifold. I spent about 4-5 hours spraying with carb cleaner, leaving for a bit, and hitting the edges with black PVC pipe (wood was too soft, and kept rounding off). It wouldn't budge a mm. Any tips on removal aside from what's already been mentioned. Engine hot maybe? Or just persevere and over a few attempts separated by driving, the carb cleaner will eventually penetrate...?

[Biotoxic]

pphilpot if you can rotate it fully clockwise or anti clockwise with one hand then it will come out, use pliers if it doesn't.

[getanammer]

Originally Posted by pphilpot

This is a great post, thanks Baffler. When I tried to do my EGR a few weeks ago, it was stuck solid in the inlet manifold. I spent about 4-5 hours spraying with carb cleaner, leaving for a bit, and hitting the edges with black PVC pipe (wood was too soft, and kept rounding off). It wouldn't budge a mm. Any tips on removal aside from what's already been mentioned. Engine hot maybe? Or just persevere and over a few attempts separated by driving, the carb cleaner will eventually penetrate...?

I had the same problem, try spraying the carb cleaner into the egr ports in the inlet manifold above the egr valve(if you haven't already).

[pphilpot]

Originally Posted by getanammer

I had the same problem, try spraying the carb cleaner into the egr ports in the inlet manifold above the egr valve(if you haven't already).

Thanks getanammer - I did, but very shyly - as in not much at all, as I didn't want to gush loads in there, and find out that it'd screw it right up. So, should I be braver with the carb cleaner down into the EGR from the inlet manifold? What if I still can't get it out, will it now be full with gunge and bad for the engine? It hasn't failed on mine, it just needs a damn good clean after 150,000 miles.

[gatos]

It will come out eventually. First time I gave up after 3 hours and lots of sweat, tears and blood. Two weeks later returned to it with more determination and this time I used the "piece of wood" trick and I had it out after 30 minutes

[Biotoxic]

+ YouTube Video

[pphilpot]

Is that to tease me? I dream of it moving that easily.

[gatos]

lol. That was hard work. THe hardest thing for me was to get mine moving clockwise and anticlockwise. Once I managed to get it moving, I just kept rotating like a screw and pulling it at the same time.
Also, Bio, what I meant with the wood, was to put is flat so the wide part of it rests on the two tops edges. Then tap one side and then the other.
The first time I tried, I did it your way, but the whole thing would not move. The next time i tried again i used the piece of wood flat, see attached images

[lswainsonl]

Just ordered mine coz mine leaking like a bitch cheers for the help

[thetomc]

Did this on my car at the weekend. I had limited success using any form of drift to free off the egr valve however my BIG set of grips (about 2 foot long) had it spinning in seconds and was then very easy to pull out. It had been liberally sprayed with penetrant and carb cleaner first mind. The egr valve was the two halves rivetted together type which I did not need to split to get it out.

This afternoon I set about ordering the rubber o-ring for the shut off throttle. No success at GSF or ECP using the volvo part number. The volvo dealership offered me a best price of £13.52 which I could not stomach so I went round the corner to Renault and paid £6.35! I have not checked back with GSF/ECP to see if they can find the renault part number.

Renault part number 7701059142 (throttle body o-ring)

Hope this helps someone save a few quid.

A great write up by the way, many thanks.