D4 VEA 'check engine' light / EGR fault thread

[keefe]

I have a 64 plate, V60 D4, with 29,000 miles on the clock.

Had the Engine Check light come up about a month ago and checked it using a mates OBD11 fault code reader and it came back suggesting that there was a problem with the EGR valve. The check light came and went over the next month until it just recently went into Limp Home Mode.

Took it into a Volvo specialist and they put their fault code reader on it and came up with the fault code ECM-P04D900, which suggests that it is a Blocked ER system. Contacted Volvo customer services and they advised me that there was an active claim for my vehicle, description "EGR Valve Oscillat" and that I would get a free repair. So on the phone to local Volvo dealer to hopefully get it sorted out.

Keith

[MikeGMT]

Well it's finally happened, engine check light flashed on, 56 plate MY16 D4 VEA with 19500mls. Was half expecting it eventually. Wouldn't mind but I've just spent most of the morning at the dealers having 2 new front tyres fitted, then got to test drive the new XC40 while there. On the the way home the TPMS flashed on, cleared that and then the check engine came on, wouldn't have thought there was any connection between the two. Happy days, back to the dealer on Monday to find out what's going on.

[juetron]

I've got a V60 2014 D4. The engine warning light came on at 34000 miles and the subsequent dealer check (conveniently when it was in for a service) has highlighted a blocked EGR valve. The car has mostly done decent length journeys rather than urban mileage.

Following collection from the service, Clive Brook in Huddersfield said they'd be in touch to rebook it in to get it fixed.

A week later I chased Clive Brook as there had been no contact. I was told Volvo UK would day for a new cooler, but I'd have to pay for a new EGR valve and pipework. Again, they said they call me back with a quote.

A week and half later I chased Clive Brook again because no quote had been sent through. The person I spoke to gave me a quote of £450 + VAT plus labour for the EGR valve and pipework. Needless to say, I was less than impressed.

Told them I wasn't going to pay that as the defective cooler was the cause of the issue and it should be resolved at no cost to me. He went away to seek further guidance.

Waiting for the return call...

[NigelDay]

Originally Posted by juetron

I've got a V60 2014 D4. The engine warning light came on at 34000 miles and the subsequent dealer check (conveniently when it was in for a service) has highlighted a blocked EGR valve. The car has mostly done decent length journeys rather than urban mileage.

Following collection from the service, Clive Brook in Huddersfield said they'd be in touch to rebook it in to get it fixed.

A week later I chased Clive Brook as there had been no contact. I was told Volvo UK would day for a new cooler, but I'd have to pay for a new EGR valve and pipework. Again, they said they call me back with a quote.

A week and half later I chased Clive Brook again because no quote had been sent through. The person I spoke to gave me a quote of £450 + VAT plus labour for the EGR valve and pipework. Needless to say, I was less than impressed.

Told them I wasn't going to pay that as the defective cooler was the cause of the issue and it should be resolved at no cost to me. He went away to seek further guidance.

Waiting for the return call...

There is something very wrong here.
I attach below the 'service actions' for my June 2015 XC60.
It tells me the EGR cooler is covered only for three years, whereas the EGR valve is covered for five years.
You need to get a printout of this for your car.
The question needs to be asked, does a defective cooler stuff the valve, or does a defective valve stuff the cooler. I don't know, but others will respond shortly, I'm sure.
What does concern me is we are now seeing Volvo deny claims for a known issue which is nothing more than a BAD design ex-factory before they eventually realised how to fix it. Very worrying.

[juetron]

Got the call back from Clive Brook. The latest is that Volvo are going to pay for the cooler to be replaced as this is a recognised fault. They also confirmed that there is no issue with the EGR valve/pipework afterall.

However, there is a fault with the induction manifold that is unconnected to the EGR/cooler fault. Despite is being 'unconnected', Volvo are willing to pay 60% towards the cost of having that fixed.

This is very strange as this is the first time a fault with the induction manifold has been mentioned. And why would Volvo offer to pay 60% for something that is outside of warranty. It's either very generous of them or something else is going on behind the scenes.

The quoted bill to resolve fully is now £225 (inc VAT). Doesn't seem too steep to get it all resolved. But it would be good to get a straight forward technical explanation. It feels like I am getting a diluted/spun message.

[MikeGMT]

Bit of a update about my check engine light flashing on last Friday. Car was booked in today, so rocked up at dealership, checked the car in and was expecting them to do diagnostics and then having to make another booking depending on what they found. But they told me they were fitting a new cooler and pipe work. Queried the EGR valve and they said it didn't need doing. 60 min. later and back on the road again, can't fault the service.

[craigv60]

Originally Posted by juetron

Got the call back from Clive Brook. The latest is that Volvo are going to pay for the cooler to be replaced as this is a recognised fault. They also confirmed that there is no issue with the EGR valve/pipework afterall.

However, there is a fault with the induction manifold that is unconnected to the EGR/cooler fault. Despite is being 'unconnected', Volvo are willing to pay 60% towards the cost of having that fixed.

This is very strange as this is the first time a fault with the induction manifold has been mentioned. And why would Volvo offer to pay 60% for something that is outside of warranty. It's either very generous of them or something else is going on behind the scenes.

The quoted bill to resolve fully is now £225 (inc VAT). Doesn't seem too steep to get it all resolved. But it would be good to get a straight forward technical explanation. It feels like I am getting a diluted/spun message.

Good news that Volvo is going to cough for the cooler.

Don't know why they're swapping the manifold, however. My guess would be this (and it is just a guess): most modern diesels with a DPF have a butterfly / flap valve either in, or close to the inlet manifold that serves two purposes: 1) it closes when the engine is switched off so the engine stops quickly & smoothly without shuddering; 2) it closes when the ECU forces a DPF regeneration, to throttle the intake and increase the combustion temperature.

I don't know where this flap valve sits in the VEA engine, but it's possible that it has got sticky and isn't working correctly. With my own 2014 V60 D4, I used to remove the boost pressure sensor every 6 months or so for cleaning. It's mounted on the inlet manifold just above where the boost pipe from the intercooler joins the manifold. The amount of oily goop and crud on the sensor was quite surprising.

As I say, that's just a guess and speculation. Hope they sort it all for you.

[thefifeflier]

Originally Posted by NigelDay

You need to ask your Volvo dealer for a printout of the 'service actions'. This will tell you which parts (EGR cooler, EGR valve) are covered (or not) and to what date / mileage. This coverage is independent of any extended warranty.

The car went in for its diagnostic check this morning. They decided it needs the cooler and pipes replaced, and the whole thing will be done under (extended) warranty on May 2nd. The workshop foreman did assure me that the car was unlikely to go into 'limp home' mode between now and May 2nd - very few do, apparently - and he also said that the pipe design has been modified so that it heats up more quickly. Does that sound about right...?

[NigelDay]

Originally Posted by thefifeflier

- and he also said that the pipe design has been modified so that it heats up more quickly. Does that sound about right...?

Not sure, I'm not a 'techie', but I'm sure others will be along soon to confirm this.

[craigv60]

Originally Posted by thefifeflier

The workshop foreman did assure me that the car was unlikely to go into 'limp home' mode between now and May 2nd - very few do, apparently - and he also said that the pipe design has been modified so that it heats up more quickly. Does that sound about right...?

They very rarely go into limp mode with the cooler / valve problem ... I drove mine for weeks with the check engine light on while waiting to get booked in, with zero effect on performance or economy.

And yes, Volvo reworked the cooler design, and the way that the engine coolant flows through the cooler, to stop it overcooling.