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xc60 2011 D3..New Rad, EGR Cooler O-ring, Leaking air heater

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Old May 21st, 2020, 16:53   #1
moes80
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Default xc60 2011 D3..New Rad, EGR Cooler O-ring, Leaking air heater

Hi All,
Hope your all well in these unsettled times.
Not posted here in a while but am hoping someone might be able to give me some advice. During this lockdown I decided to de-coke throttle body, egr valve, egr cooler, replace radiator, and fix a slight oil leak on my volvo xc60 D3 2011 (manual)

Starting with the radiator, old one was weeping at bottom corners. The rad itself is in good condition, do you think I should get it resealed or buy a new one? assuming I decide to go for a new rad I was looking at Hella(£120) or Valeo(£330) as the brand, does anyone have any experience with Hella rads...are they any good? The price difference is too great to ignore and I'm leaning towards the Hella. EuroCarParts advertise Hella 376787121 as the replacement rad but it also says it's for engine D5204T3, I have the D5204T2. They told me it will fit, can someone advice on this, as I don't want to buy it just to find it won't fit the D5204T2 engine.

Another topic is the EGR valve and cooler, took these out to de-coke, the original metal seals are in good condition so will be using these again (unless someone says otherwise). At the back of the egr cooler is a hole (male)which engages with a pipe (fitted to the engine block,female), on this pipe is an o-ring. This o-ring seals between the pipe and cooler, stopping coolant leaking. I am having difficulty identifying that o-ring. Called one volvo dealer, after almost 20 minutes of trying to convince him it did exist he gave me a price of £52+vat I think he just gave me some random price. Called a different volvo dealer and they had no idea there was such an arrangement and could not understand what I was after . Has anyone here replaced that o-ring? if so can you please tell me where I can buy it from or the OEM number so I can identify a replacement.

Finally, have a slight oil leak at the small heater which fits into the air duct running from air flow meter to turbo. It had a jubilee clip on it but this does not keep the oil in. I have seen a video on utube where some one used gasket paste to make the seal. Has anyone tried this and found it worked/did not work. Or anyone got any better ideas for making the seal. it's not a case of buying a new part as it's a design flaw.

Thanks in advance for your help. Stay safe

Last edited by moes80; May 21st, 2020 at 17:03.
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Old May 26th, 2020, 16:37   #2
Baal
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Originally Posted by moes80 View Post
Hi All,
Hope your all well in these unsettled times.
Not posted here in a while but am hoping someone might be able to give me some advice. During this lockdown I decided to de-coke throttle body, egr valve, egr cooler, replace radiator, and fix a slight oil leak on my volvo xc60 D3 2011 (manual)

Starting with the radiator, old one was weeping at bottom corners. The rad itself is in good condition, do you think I should get it resealed or buy a new one? assuming I decide to go for a new rad I was looking at Hella(£120) or Valeo(£330) as the brand, does anyone have any experience with Hella rads...are they any good? The price difference is too great to ignore and I'm leaning towards the Hella. EuroCarParts advertise Hella 376787121 as the replacement rad but it also says it's for engine D5204T3, I have the D5204T2. They told me it will fit, can someone advice on this, as I don't want to buy it just to find it won't fit the D5204T2 engine.

Another topic is the EGR valve and cooler, took these out to de-coke, the original metal seals are in good condition so will be using these again (unless someone says otherwise). At the back of the egr cooler is a hole (male)which engages with a pipe (fitted to the engine block,female), on this pipe is an o-ring. This o-ring seals between the pipe and cooler, stopping coolant leaking. I am having difficulty identifying that o-ring. Called one volvo dealer, after almost 20 minutes of trying to convince him it did exist he gave me a price of £52+vat I think he just gave me some random price. Called a different volvo dealer and they had no idea there was such an arrangement and could not understand what I was after . Has anyone here replaced that o-ring? if so can you please tell me where I can buy it from or the OEM number so I can identify a replacement.

Finally, have a slight oil leak at the small heater which fits into the air duct running from air flow meter to turbo. It had a jubilee clip on it but this does not keep the oil in. I have seen a video on utube where some one used gasket paste to make the seal. Has anyone tried this and found it worked/did not work. Or anyone got any better ideas for making the seal. it's not a case of buying a new part as it's a design flaw.

Thanks in advance for your help. Stay safe

At first, D5204T2 and 4T3 are the same engines, the only difference is that the 4T3 has start-stop function and a little bit of tweaked ECM.

Radiator: buy a new one don't cheap out on a rad cause it will not end well. The one from D5204T3 will fit nicely.

Air duct: I have done that, sealed the damn thing and no more leaks so, yes it does work.

EGR: The new one costs about 280€ just get a new o ring if it exists. If the metal seals aren't burnt use the old ones they should still be fine.

Last edited by Baal; May 26th, 2020 at 16:49.
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Old May 26th, 2020, 17:44   #3
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Originally Posted by moes80 View Post
Hi All,

Starting with the radiator, old one was weeping at bottom corners. The rad itself is in good condition, do you think I should get it resealed or buy a new one? assuming I decide to go for a new rad I was looking at Hella(£120) or Valeo(£330) as the brand, does anyone have any experience with Hella rads...are they any good? The price difference is too great to ignore and I'm leaning towards the Hella. EuroCarParts advertise Hella 376787121 as the replacement rad but it also says it's for engine D5204T3, I have the D5204T2. They told me it will fit, can someone advice on this, as I don't want to buy it just to find it won't fit the D5204T2 engine.

Thanks in advance for your help. Stay safe
"HELLA" is a very good Automotive brand and make many OEM parts for the likes of VAG, BMW, SAAB, etc... I've personally used their A/C rads & receiver driers on two occasions... BMW 540i Touring and SAAB 9-5 AERO... few years ago now but I still remember they were of very high quality and fitted perfectly without any drama.
To be honest I'm a little surprised at the price difference between Hella & Veleo radiators ?!?! It's not as if it some complex electronic part
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Old May 26th, 2020, 23:08   #4
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Originally Posted by Auto Addict View Post
"HELLA" is a very good Automotive brand and make many OEM parts for the likes of VAG, BMW, SAAB, etc... I've personally used their A/C rads & receiver driers on two occasions... BMW 540i Touring and SAAB 9-5 AERO... few years ago now but I still remember they were of very high quality and fitted perfectly without any drama.
To be honest I'm a little surprised at the price difference between Hella & Veleo radiators ?!?! It's not as if it some complex electronic part
No nothing like that, Valeo is OEM for Volvo that's why.
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Old May 27th, 2020, 11:25   #5
moes80
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Originally Posted by Baal View Post
At first, D5204T2 and 4T3 are the same engines, the only difference is that the 4T3 has start-stop function and a little bit of tweaked ECM.

Radiator: buy a new one don't cheap out on a rad cause it will not end well. The one from D5204T3 will fit nicely.

Air duct: I have done that, sealed the damn thing and no more leaks so, yes it does work.

EGR: The new one costs about 280€ just get a new o ring if it exists. If the metal seals aren't burnt use the old ones they should still be fine.
Hi Baal,

Thanks for the advice. I ended up going with the new Hella. The gaskets around the egr valve and throttle body are good as new, a very gentle wipe removed the thin carbon ring on the inner edges so good to go there.

I still haven't been able to identify the o-ring on the coolant supply pipe on the egr cooler....spoke with volvo..several in London, Bristol, Gloucester, Birmingham, Oxford and none were able to help. I have decided to source the O-ring independently by sending it to an seals specialist and for them to size-up select the material and supply. Hopefully they will get back to me in the next few days. Will update this site in due course.

Also ordered some K2 seal paste (exhaust system) to seal that annoying leak around the air intake heater.

Car is off the road at the moment, waiting for parts to be delivered. Everything crossed it all goes back and lives once again
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Old May 27th, 2020, 11:30   #6
moes80
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Originally Posted by Auto Addict View Post
"HELLA" is a very good Automotive brand and make many OEM parts for the likes of VAG, BMW, SAAB, etc... I've personally used their A/C rads & receiver driers on two occasions... BMW 540i Touring and SAAB 9-5 AERO... few years ago now but I still remember they were of very high quality and fitted perfectly without any drama.
To be honest I'm a little surprised at the price difference between Hella & Veleo radiators ?!?! It's not as if it some complex electronic part
Hi Auto Addict,

Thanks for the advice, went for the Hella. I assumed on par with Baals post that the reason why Valeo are so expensive is because they are OEM for this part. Visual comparison between the Hella and the Valeo you would not be able to tell then apart.
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Old May 27th, 2020, 11:38   #7
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Hi Auto Addict,

Thanks for the advice, went for the Hella. I assumed on par with Baals post that the reason why Valeo are so expensive is because they are OEM for this part. Visual comparison between the Hella and the Valeo you would not be able to tell then apart.
You're welcome over £200 saved. I call that a WIN !
Both probably made in the same factory however one packaged in a very expensive "OEM" box
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Old May 27th, 2020, 20:03   #8
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Originally Posted by moes80 View Post
Hi Baal,

Thanks for the advice. I ended up going with the new Hella. The gaskets around the egr valve and throttle body are good as new, a very gentle wipe removed the thin carbon ring on the inner edges so good to go there.

I still haven't been able to identify the o-ring on the coolant supply pipe on the egr cooler....spoke with volvo..several in London, Bristol, Gloucester, Birmingham, Oxford and none were able to help. I have decided to source the O-ring independently by sending it to an seals specialist and for them to size-up select the material and supply. Hopefully they will get back to me in the next few days. Will update this site in due course.

Also ordered some K2 seal paste (exhaust system) to seal that annoying leak around the air intake heater.

Car is off the road at the moment, waiting for parts to be delivered. Everything crossed it all goes back and lives once again
Excellent news, you just saved yourself 460£

About the oil return valve, be very careful at removing the sensor, the plastic holding it in place is very brittle and could crack.

Now I have a question for you seeing that we have the same engine and all that.

Can you tell me if you hear a hiss on your Volvo when accelerating normally with your windows down, cause I have the same engine D5204T2 in my V60 and I really would like to know if this is normal.

Last edited by Baal; May 27th, 2020 at 20:11.
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Old May 28th, 2020, 10:44   #9
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Originally Posted by Baal View Post
Excellent news, you just saved yourself 460£

About the oil return valve, be very careful at removing the sensor, the plastic holding it in place is very brittle and could crack.

Now I have a question for you seeing that we have the same engine and all that.

Can you tell me if you hear a hiss on your Volvo when accelerating normally with your windows down, cause I have the same engine D5204T2 in my V60 and I really would like to know if this is normal.
Hi Baal,

YES I DO !
but i was hoping my current super service would somehow rectify that. In fact as I am still waiting for the new parts to arrive I have decided to trace the vacuum lines and see if I can spot a leak. Also worth mentioning is that when I removed the front air duct with the oil return valve in it, I noticed the jubilee clip at the turbo end was very loose so I'm hoping that may have been the cause.
Just to clarify, no hissing whilst idling, accelerating (no matter how gently or aggressively) you get a hissing bit like a dump valve but without the dumping....just hissing. this only started when my car went into a garage for some body work got it back hissing, wasn't doing it before, complained and they told me not their problem

Regarding removing the oil return valve, I did as per the youtube video and heated the housing with a hair dryer...worked a treat

Will keep you informed regarding the hissing. Take care.
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Old May 29th, 2020, 12:01   #10
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Hi Baal,

YES I DO !
but i was hoping my current super service would somehow rectify that. In fact as I am still waiting for the new parts to arrive I have decided to trace the vacuum lines and see if I can spot a leak. Also worth mentioning is that when I removed the front air duct with the oil return valve in it, I noticed the jubilee clip at the turbo end was very loose so I'm hoping that may have been the cause.
Just to clarify, no hissing whilst idling, accelerating (no matter how gently or aggressively) you get a hissing bit like a dump valve but without the dumping....just hissing. this only started when my car went into a garage for some body work got it back hissing, wasn't doing it before, complained and they told me not their problem

Regarding removing the oil return valve, I did as per the youtube video and heated the housing with a hair dryer...worked a treat

Will keep you informed regarding the hissing. Take care.
Thank you for the information, I knew it wasn't normal. I've changed all of my turbo hoses except the one under the engine maybe that's the one causing a leak.

Get a new jubilee clip, it got it from Volvo for 12€ It's a common issue on these engines.
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