D4 VEA 'check engine' light / EGR fault thread

[spaceman2844]

Originally Posted by Hirsts

Just joined today as we have had this issue come up today. Dealership are saying they are utterly surprised, have never heard of such an issue and quoted us £1,400 to replace egr valve and cooler. Will be going after Volvo UK next. Thank you all for your posts. I hope to find the picture that confirms if the car has already hd any egr fixes.

Car is 65 reg D4 XC60

Photos of my engine before and after the previous dealer fix with new pipework are here:

https://www.volvoforums.org.uk/showp...postcount=1539

[Chrisv60]

Originally Posted by spaceman2844

Photos of my engine before and after the previous dealer fix with new pipework are here:

https://www.volvoforums.org.uk/showp...postcount=1539

Another giveaway that work has been done is that the coolant hoses at the front of the engine are fastened on with jubilee clips rather than the original Volvo spring clips.

[RDesign4Life]

So what's the verdict on the final Volvo fix for the this whole EGR cooler debarcle?

Is it proving effective in the round or is every 2.0l VEA engine ever produced from 2014 to 2017 going to die prematurely at enormous expense to the owners?

One of the things that attracted me to the Volvo was the reputation for their diesel engines to crack on to 200k miles and beyond.

Reading this thread I'm gutted.

[belgian]

Originally Posted by RDesign4Life

So what's the verdict on the final Volvo fix for the this whole EGR cooler debarcle?

Is it proving effective in the round or is every 2.0l VEA engine ever produced from 2014 to 2017 going to die prematurely at enormous expense to the owners?

One of the things that attracted me to the Volvo was the reputation for their diesel engines to crack on to 200k miles and beyond.

Reading this thread I'm gutted.

They sit still and are convinced that the problem will go away by itself when these cars are good for the bin. i believe volvo switched to ADblue on newer diesels and since Volvo is going electric all the way in the future anyway, nobody cares about the old diesels any more.

I have had twice the problem of EGR cooler and know that the 3rd is only a matter of time. I was a loyal volvo diesel fan until this VEA engine came around with it EURO6 EGR technology that was a recipe for guaranteed problems. The engine itself is not to blame; only the emissions control is a nuisance.

[Miyo360]

An update to my previous updates...

Brief recap:

1. Approx 3 weeks ago, fault code p04D9 shows up. Took it dealer. They said unlikely to be EGR (as it had been replaced 3 times already and had "final fix"), so went looking for other problems and found a break in this big pipe at the back of the engine (arrow showing the point of the break), which is causing "low flow" - pipe replaced for ~£300.
2. Two days later, fault code P04D9 reappears. Took it back. This time they found a split in the diaphragm of the EGR actuator. Replaced with a working actuator from another customers stuck EGR valve. Cost ~£275

Now, one week later, the same fault code reappears. Fantastic! I've spent £600 fixing nothing. Hmm, I wonder what else could be the problem? Oh yeah, the f*%&ing EGR valve and cooler! I called the dealer but the service manager is away this week and I don't want to deal with anyone else, so I'll speak to him when he's back. Meanwhile, I'm left considering my options.

I know cleaning the valve and cooler is the sensible option, but I don't feel confident removing both and putting them back, even having watched the excellent YT video here. I'm happy to do the cleaning work, so may take it to an indy, ask them to strip them out, clean up, then take them back a few days later to re-fit.

I found a 2nd hand cooler and valve from ebay, but this will also need cleaning, so don't see much point in ending up with 2, except that I could keep one clean set "on the shelf" for when the working set needs cleaning in 6000 miles time - it would get the car back on the road quicker.

Sadly, this looks like the only solution. Keep cleaning or replacing your valve/cooler each year.

[RDesign4Life]

Originally Posted by Miyo360

An update to my previous updates...

Brief recap:

1. Approx 3 weeks ago, fault code p04D9 shows up. Took it dealer. They said unlikely to be EGR (as it had been replaced 3 times already and had "final fix"), so went looking for other problems and found a break in this big pipe at the back of the engine (arrow showing the point of the break), which is causing "low flow" - pipe replaced for ~£300.
2. Two days later, fault code P04D9 reappears. Took it back. This time they found a split in the diaphragm of the EGR actuator. Replaced with a working actuator from another customers stuck EGR valve. Cost ~£275

Now, one week later, the same fault code reappears. Fantastic! I've spent £600 fixing nothing. Hmm, I wonder what else could be the problem? Oh yeah, the f*%&ing EGR valve and cooler! I called the dealer but the service manager is away this week and I don't want to deal with anyone else, so I'll speak to him when he's back. Meanwhile, I'm left considering my options.

I know cleaning the valve and cooler is the sensible option, but I don't feel confident removing both and putting them back, even having watched the excellent YT video here. I'm happy to do the cleaning work, so may take it to an indy, ask them to strip them out, clean up, then take them back a few days later to re-fit.

I found a 2nd hand cooler and valve from ebay, but this will also need cleaning, so don't see much point in ending up with 2, except that I could keep one clean set "on the shelf" for when the working set needs cleaning in 6000 miles time - it would get the car back on the road quicker.

Sadly, this looks like the only solution. Keep cleaning or replacing your valve/cooler each year.

The picture of the fresh air intake pipe that you have linked to doesn't look like an XC60 D4 2.0 VEA engine. I replaced mine a few weeks ago as the engine cover fixings had snapped. New part was about £120 delivered iirc and took maybe an hour tops to fit taking my time. Didn't look like yours though it was this one...

https://www.allcarpartsfast.co.uk/ge...resh-air-pipe/

https://a.allegroimg.com/s1024/0c924...715e6b3ec9a091
https://volvozone.sk/files/cache/pro...vz-800x600.jpg

If they charged you 300 notes to replace the fresh air pipe presumable there was a standard £100+ diagnostic fee on top of the actual work done?

[Miyo360]

Originally Posted by RDesign4Life

The picture of the fresh air intake pipe that you have linked to doesn't look like an XC60 D4 2.0 VEA engine.

Sorry, I just googled the engine for a picture that I could mark up. It looked right at first glance, but guess it may not be the exact engine.

Re the price, I'm not sure the diagnostics were included. I understand the hourly rate of a Volvo mechanic is around £180 (that's Twickenham) so add the £120 for the pipe, the £300 looks about right.

[spaceman2844]

Originally Posted by Miyo360

An update to my previous updates...

I know cleaning the valve and cooler is the sensible option, but I don't feel confident removing both and putting them back, even having watched the excellent YT video here. I'm happy to do the cleaning work, so may take it to an indy, ask them to strip them out, clean up, then take them back a few days later to re-fit.

I found a 2nd hand cooler and valve from ebay, but this will also need cleaning, so don't see much point in ending up with 2, except that I could keep one clean set "on the shelf" for when the working set needs cleaning in 6000 miles time - it would get the car back on the road quicker.

Sadly, this looks like the only solution. Keep cleaning or replacing your valve/cooler each year.

Sounds like a good plan to get an indy to remove and refit the cooler with you cleaning it. You need to get the EGR / cooler gasket as it will need replaced. I ordered the other gaskets for the EGR pipe and inlet pipe but didn't need to use them. I got all the gaskets from Autodoc but your dealer parts dept could get them for you.

My car had the "definitive" fix 5 years ago, so it was 5 years before the P04D9 error returned so it's probably unlikely you'll need to clean the cooler every year. Don't forget you'll need to refill with Volvo coolant, so price that in. I drained the system and it took 5 litres of premixed coolant to refill.

Good luck with it!

[Miyo360]

Originally Posted by spaceman2844

I got all the gaskets from Autodoc

Can you share a link to the various gaskets you ordered please?

My car had the "definitive" fix 5 years ago, so it was 5 years before the P04D9 error returned

Interesting. Approximately how many miles did you cover in those 5 years? And was there much short/town driving in that mix?

Don't forget you'll need to refill with Volvo coolant, so price that in. I drained the system and it took 5 litres of premixed coolant to refill.

Again, can you share a link with what you bought? Cheers!

[pastie321]

Had the dreaded EGR issue pop up on my 2016 XC60 D4 a few months ago, accompanied by loss of power at low revs and a fluctuating rev counter at idle.

Took it to my local dealer and quoted £1,400 for new valve and cooler - told it was caused by the previous owner travelling low miles - 27k in 5 years.

After finding this thread and doing my own research, talking to a few mechanics and owners of other vehicles, decided to go for an EGR delete at £400. Touch wood have driven over 1,000 miles since with no issues whatsoever