2016 V60 D4 Smoke from engine bay

[samjay]

I've got a 2016 V60 D4 on 163k miles, and there is smoke coming from the back of the engine bay.

Video here - https://youtu.be/6p-dJgilLRs

I had this issue a month ago and had the rocker cover replaced, and it seemed to be ok until this week.

I should also note that I had the EGR valve+cooler, exhaust pressure sensor and swirl flap motor replaced 5k miles ago

This time it was after an hours drive in London, so lots of 20mph start/stop traffic (engine always running). When I finished my journey the radiator fan was going full blast, and the area around the back right of the engine where the smoke was coming from seemed to be very hot.

Also when I had this issue before, I could swear there was a metallic rattling/squeak (maybe like a spray paint can) coming from the engine until it cooled down somewhat. Not happened since then, but thought I heard something vaguely similar for a moment this time.

Also whenever I start the car and the fan is set to on, I can smell exhaust fumes in the cabin. Doesn't happen as much when the car is warm and running

Anyone got any ideas?!

[GrahamBrown1]

Sounds very much like a split EGR pipe and common issue. Leaking fumes into the cabin is usually down to this.

[RDesign4Life]

Yep looks like EGR hose leak. Here's my video from when it happened to my previous XC60...

https://youtube.com/shorts/5haUxu7eY...d93_8FLmlETO69

It's the concertina pipe section.

I also experienced smells in the cabin and had periods of weeks where there would be no smoke at all but then it would return.

[samjay]

I’ve just spoken to my mechanic and the EGR exhaust pipe was replaced in November when I got the car.

Could it break this quickly?

Obviously going to take it in to get looked at, but just waiting for a date they have availability to check it

[GrahamBrown1]

You would like to think not but it is a common failure. They seem to fracture at the flange or the ones I’ve seen have. Obviously your guy needs to have a look be interesting to hear what he finds. You’ve had the cam cover replaced there isn’t really anything else I can think of causes this problem on these.

[RDesign4Life]

Originally Posted by samjay

I’ve just spoken to my mechanic and the EGR exhaust pipe was replaced in November when I got the car.

Could it break this quickly?

Obviously going to take it in to get looked at, but just waiting for a date they have availability to check it

Was it replaced with a genuine Volvo part? There's that much crap getting peddled as 'OEM' quality these days that it's not worth the risk.

[samjay]

Originally Posted by RDesign4Life

Was it replaced with a genuine Volvo part? There's that much crap getting peddled as 'OEM' quality these days that it's not worth the risk.

100% it would have been replaced with a genuine part. My mechanic is an independent Volvo specialist and only uses Volvo parts!

[Sotosound]

Sometimes, mechanics make mistakes, and sometimes they're supplied with faulty parts.

When my P2 V70 D5 had its turbocharger replaced, the initial replacement was faulty.

When a family member recently bought a new gas fire, it leaked. Everyone pointed towards the manufacturer as having supplied a faulty fire but, in the end, it turned out to be the result of a mistake made by the fitter.

[samjay]

Originally Posted by Sotosound

Sometimes, mechanics make mistakes, and sometimes they're supplied with faulty parts.

When my P2 V70 D5 had its turbocharger replaced, the initial replacement was faulty.

When a family member recently bought a new gas fire, it leaked. Everyone pointed towards the manufacturer as having supplied a faulty fire but, in the end, it turned out to be the result of a mistake made by the fitter.

I appreciate everything isn't 100% certain all the time so could well be the case, but they're better than most!

[samjay]

So I bought an endoscope camera from Amazon as I wanted to do some investigating around the EGR pipe.

I've made a short video with 2 clips - https://youtu.be/eW-IoAdNwvo

Clip 1 follows the EGR pipe to the connection at the back of the engine.
Clip 2 explores lower down in the engine below where the smoke was coming from.

Hopefully it gives an idea of where in the engine the camera goes.

And for those who don't want to watch a video, I've got some photos.

Picture 1 is the EGR pipe connector at the back of the engine
Picture 2 is lower down in the engine below where the smoke was coming from.
Picture 3 is the EGR pipe

Would be interested to hear if anyone has any thoughts!

Also I highly recommend getting an endoscope camera. Connects to a phone and only costs £20!