Cleaning the EGR on a euro4 Volvo D5

[@MattLawrencefx]

Thanks for taking the time to demonstrate this... just cleaned the EGR and pipework on a 2010 XC90 with 125k miles on the clock after watching your video. EGR was in a similar gunked up state to yours. Was able to clean without removing air filter so literally just 5 pipe clips to undo. Volvo main dealer wanted to charge me £1800 to replace Valve and cooler, did the job myself in under 3 hours for £10! (just the cost of carb cleaner) Car now drives like new. Thank you so much!!!

[@hermanmunster3358]

Thanks for the vid mate. I have a Euro 4 D5 with 95k on the clock. I followed the instructions, but also unbolted the throttle body from the right side of the egr, and gave it a good clean with liqui moly intake cleaner, and a toothbrush, and managed to remove about 98% of deposits. I also cleaned the fat plastic intake pipe that attaches to the left side of the egr, and the intake as far inside as I could with a dessert spoon. Mine wasn't quite as bad as yours, but it was still well caked, about 5mm around the intake pipe, and about the same on both sides of the egr valve and intake. Scraped out as much crap as I could reach, and soaked all areas with liqui moly, and it is now much much cleaner. The throttle body is back to bare metal, as is most of the egr. And the intake pipe is completely clean. I must have removed a good 1.5 llb's of crap, so I'm well pleased its done now. It is a dirty job, but a job well worth doing. But yeah, WEAR GLOVES!!!

[@rablark268]

I'll be doing this next week!

[@alexmanojlovic768]

I have a 2008 D5 185 Euro4 (with 97k miles) & just had the EGR to inlet manifold off, and de-gunk'ed it (only half as blocked as yours). Thanks for the advice re throttle/EGR side. I was also looking at the myriad pipes/fittings etc, as I need the car prettty much daily, so you're probably saving me a shed load of time (most of the forums have pre Euro 4 163hp versions of this engine, and yours is the 1st "HowTo" I've found that covers our engine. Cheers Sam!! :)

[@samuelellisuk]

+Alex Manojlovic Not a problem, this engine has 138k on it. If i am being honest the intake side where the boost pipe from the intercooler goes was not all that dirt so cleaned up reasonably easy. The real dirt was on the side that goes to the intake manifold, that was just as bad as the manifod to egr pipe, I would reccomend using a scre driver to try and remove the worst before attacking it with carb cleaner

[@BeNjOOO64]

Good job, I did the same cleaning last week on my XC70 from 2006. there was only a 2 cm diameter gap at the inlet of the EGR valve.

[@gavinstirling7088]

I know this is 4 years ago but thanks all the same. I'm working away on our old XC90 and found the throttle body, egr valve and pipework is just as bad as yours. I'm actually working in the vicininity to repair the TF80-SC valve box but that's a while other story. I'll check out your other uploads soon, cheers!

[@trademarkuk01]

Great down to earth home video.

[@shuttersoundphotos]

Just done mine and wow it was rather full. Thank you so much for the guide

[@dudczwoj]

Awesome mate. Just bought my first one and I have the same issue. Will do a full EGR clean and see how it goes. Cheers!

[@SergioMartinez-fn4gi]

good job, I already did the egr cleaning by disassembling it completely and the pipes I extended to disassemble the intake manifold was dirty too but it had oil mixed with soot, ?? I disassembled and checked the oil decanter in case the membrane was broken, and I decided to install a catch can, the engine is good and happy

[@edjenks93]

great video just spent the afternoon doing mine after seeing this, much better now =)

[@johnlang3233]

Don't forget the euro 4 engine oil level was revised by Volvo - make sure the oil level is not above the top three "XXX" marks on the dipstick - revised capacity is about 5.5 litres, no more.

[@Joni0000]

Why not?

[@jabt8197]

Very good video. I’ve got a 2003 xc90, 163cv. It runs great, but I will follow your advice as soon as I can. Thanks a lot!

[@MrKoblepot]

Just did it bro, was full of dirt inside, thanks a lot 😊

[@julianking3517]

I carried out this work on a 2005 V70 D5 before a holiday in 2016. I found a really good solution to the all too common EGR problem. After the holiday I broke the car into pieces and sold the engine including the EGR to a Volvo engine dealer. Never again do I wish to own a Volvo with a D5 engine

[@joestiffcock2480]

fyi. Egr are on all Tdiesels and most if not all modern petrol engines too. And considering you path of logic,i suggest using bicycle.

[@jakkjo263]

Yes! Finally another man with a Euro4. My V70 has 215k on it now, and my egr look just like this, glad to hear you noticed a difference after cleaning it. I'm definitely going to clean mine too.

[@samuelellisuk]

yep it is a noticeable difference - i would recommend trying to remove as much as possible by hand/scrape out with a plastic tool before carb cleaner though as the carb cleaner makes it a lot more messy.

[@olexandervolynets1884]

Cheers mate . Had some spare time today to have a look into mine. Oh god .... Same as yours Just cleaned the pipe today, tomorrow going deep into it, a bit further than you did . Thanks for motivation

[@KeyboardThumper]

Wicked vid mate, can‘t wait to have a go.

[@macolganjames5937]

Good detailed and informative video. Something else I need to do and now know how to do it. Many thanks for sharing 👍

[@tomjones8715]

Great help! I took the throttle body off…wasn’t that much more work!

[@danwilson38]

Going to give this a go at the weekend. Mines on 187k and never been cleaned 😂

[@MrImarcus]

Bloody great video!! Ive been educated and entertained and by the sound of it from Yorkshire! Great car too, I had a 2003 D5 with 270k on it. Was probably my favourite car and most economical! Wished Id checked the egr pipes now... Lookin forward to your next vid !

[@samuelellisuk]

Cheers fella - Aye im from Yorkshire. TBH this one is not the greatest example of a s60 D5 as it has had many many owners who appear to have ignored/bodged a lot on it but I cant really complain as it keeps going

[@MrJimbo3321]

Brilliant vid mate, keep it up. Thanks.

[@alouisschafer7212]

It gets really fun when the soot and grime gets so bad that it clogs all the way up into the intake runners and swirl flaps because then eventually the swirl slaps will coke up so bad that they jam up or become stiff enough for the actuator to throw a code, especially when they are coked up enough that the actuator cant move all the way to the end stops i.e 0% open and 100% open. Because now you are royally screwed and have to disassemble half of the engine to get to the swirl flaps in the first place.

[@A.Vasiliauskas]

guys.... when you cleaning egr also take engine air intake top cap, cover. you will surprised so mutch when youll see the cloged holes witch feed cylinders with air under pressure.

[@iceincube]

Does anyone know- does intake top cap needs some gaskets to be replaced after opening it up- or not? And how much diffrence it would make? As I understand from video- by removing everything before intake it already has great effect.

[@darkpuppetplayer5722]

You can also brakecleanerspray to clean the EGR from inside.

[@matinaator101]

Great video

[@colganincardiff]

Top lad. Yaaarksha yarksha

[@anguspatterson9449]

Nice one I've got same engine glad for tips cos my computer is on top of airbox and I badly need to clean my intake manifold and this video is excellent, ps I'm wearing gloves when I do 🙂

[@duraiddlimi9032]

thanx for the info. Itwould be great to tell what fault codes was in the car.

[@madmac-bq6ti]

Just done mine, heavy 'de greaser and flat head long screw driver. Scrap and wipe until clean. Time will tell :)

[@tauron97]

que trabajo lleva la limpieza,espero que se note en algo del vehiculo,un saludo.

[@EllwinG075]

Thanks for the video, I'll give it a try.👍👍

[@HORNET6]

Just about to buy one of these euro 4 D5's so this is a great heads up. Do you know if there is a way to do away with the EGR altogether and blank off the exhaust?

[@gavinstirling7088]

Thought about that too but it might nudge up the emissions beyond what's accepted for the MOT test here in the UK at least.

[@SeamusFoley-d4r]

Volvo years ago use to be a great car because they were petrol and Swedish .now they are fckn diesel and french .please stay to fuck away from them and read my comments twice .

[@stephendent178]

Mine has a turbo flutter / stutter is it caused by a clogged egr

[@darkpuppetplayer5722]

Why dont you use a industrial vaccumcleaner?

[@JS-ri2rx]

Good effort

[@tonyh4233]

Great Video, I apologise in advance id you already said in your video but what was the vehicle mileage please

[@krisjanislejnieks8867]

Good video. I did the same plus intake manifold as much as possible. But it was a lot more wrenching. All injectors out, fuel supply lines out, valve cover (which is also intake manifold) off. Checked swirl flaps, replaced copper gaskets for injectors. But well worth it. Now 18 months later I've observed some oil leak from turbo. I will replace high pressure side silicone gaskets on turbo air outlet, but seems that I have very minor overpressure in crankcase, that could be the cause. Idk, have you experienced oil leaks from turbo? Looks like even there is something dripping from air intake (underpressure) side. But I cant imagine how thats possible.

[@krisjanislejnieks8867]

What to check in pcv system? Oil trap blocked perhaps? Have you had any issues there?

[@marekcerny4082]

Great..btw why don't you guys use a vac cleaner while scraping the mess? Cheers.

[@rhyason]

You can actually remove the whole valve assembly quite easily. When you get all the hoses off, it just three or four more bolts and it is off.

[@icandoitycandoit613]

Philipp Schussmann do you have to drain the cooling system? Read this som where else

[@costinconstantin4242]

Avoid long idle, low rpm driving and do rev the engine to 3500-4000 from time to time. Even better, EGR off.

[@mamadidikgale6435]

My 2006 D5 has black smoke on idling and it doesn't boost at all. OBD says DPF faulty. Tried to change that but still. Now it's been parked for a year.

[@khimaros]

I removed the pipe that connects the EGR to the intake and carried it though my living room. The temperature difference liquified the carbon deposits which tipped all over the cream coloured carpet! So just be careful with the pipe and the contents, it's disgusting stuff!!!

[@hermanmunster3358]

Well, you live and learn.

[@josebellvis8892]

Great video! I have 2.4 D 163 HP Euro IV... which is similar to yours. I have issue with a noise (when opening the car) "crick crick crick..." That I think is the valve actuator. As the valve is "normally open" what is the effect of having this issue which I think doesn't let the valve to fully close? Will this problem show an error code? (The sensor of this actuator doesn't see anything wrong).

[@raimond55567]

I think i'm having the same issue, asked around from a workshop and they said that its quite common that the valve won't close properly when it has to and that will direct the dirty air to the system or something, causing power loss.

[@josebellvis8892]

@@raimond55567 In my case, it wasn't the egr, was the electronic turbo actuator whose plastic gears broke down.

[@roperry7949]

Hello, great video, many thanks, please I have the engine disassembled but I can not remove the EGR, can you explain how you can do to free the corrugated gold pipe on the back that goes from the engine exhaust to the EGR? The screw band does not open the collar that holds the gold tube.

[@jchalmers28jc18]

Hi there good vid very useful. Do u no if egr valve is clogged would it affect dpf filters as mines not regenerating

[@dillen66]

Great video! One question, after loosing the clips, was it any difficulties to remove the pipe between the EGR and the intake? I planned to do this myself but I became a bit uncertain whether I needed to remove something else to make enought room to remove the pipe.

[@samuelellisuk]

it was not that easy to remove but that is only really because of the rubber tube bits that are under the clips, it comes out but you do need to wiggle it out, same as refitting - is tight. Sorry if this doesnt make a lot of sense but it will make more when you try it yourself

[@dillen66]

It makes sence, thank you :)

[@phildevoid8495]

Thanks for a great video and well done!I must add that I noticed in the beggining of the video that you are missing the arm connected from the motor to the swirl flap, you are probably aware of that or I might be wrong.Anyhow, just a heads up, you can pick up a new arm from ebay or something.It is worth it as the combustion improves and you get more MPG.If you ask Volvo they will only replace the swirl flap itself wich costs a fortune (new arm included :)

[@samuelellisuk]

Hi - thanks for the headsup, I know about the swirl flap bar - the problem i have is where the bar connects on the engine is worn down so even a new bar pops straight off (the bar is the dog bone shape so its the newer style) it is something that i am trying to sort out as i know the engine runs a lot better with the bar

[@rhyason]

Hi, I actually have the same problem. As an interim fix, you can put the lever on backwards. That will last for a couple of months. What I found on german forum was a guy that used a M3 Balljoint that is normally used for RC planes and such. That is what I am going to do. At least that will give you a metal ball with a plastic pan and when that pan wears down it is easy to replace.

[@EllwinG075]

+samuelellisuk. Hi I also had the same problem on my S60 D5, I bought the part from Volvo (the little bar to connect to the motor and the swirl flap). The problem I had was it kept coming off😖😖😖. Had to come with a plan. 🤔🤔🤔 I drilled a small hole on the connecting bar and the ball end on the motor and put a small wire to keep them in place👍👍👍. Job done it's never coming off. I hope this make sense.

[@daskobal]

lol, what would mine look like with 250,000... but mine is the euro 5 I think, think i have a job to do this week end. BTW does anyone know what the stepper motor and link on the left side of motor is, it seems to open a oil dump valve on start up but my connecting rod keeps falling off...there is a quick shot of the stepper motor @2:08. thanks for the video, that is a lot of carbon build up..

[@barryflannel3182]

It operates the swirl flaps which sit inside the intake manifold (the black plastic cam cover). There is a short plastic link arm that connects the swirl arm with the motor, and this is renowned for popping off. Search the web for solutions on how to fix this.

[@adriang6373]

Nice video, I carried out this procedure on my 2011 XC90 D5 yesterday evening, on the commute to work this morning it was running smoother but I was getting a burning smell in the cabin that progressivly got stronger. Did you get any smells after the clean on yours? I checked under the bonnet, everything looks fine and the exhaust isn't smokey...I suspect some crud has made its way into the DPF.

[@leedsdashcamnetwork9577]

great little video fella... my XC90 is in at a garage for dpf filter issues which I'm sure is gonna be related to the swirl flap, egr valve and intake manifold all being full of crap. gonna leave the swirl flap for the time being due to the time and effort (£) involved. didn't realise how sensitive the d5 euro 4 is to oil choice also! not sure yet whether the dpf is full of soot or ash.... have you noticed any DPF issues? "soot filter full" & limp mode? your video might actually help me get my hands oily as they don't normally... I usually pay someone else for that! Cheers... I'll be watching.

[@samuelellisuk]

Sorry it took a bit to get back to you. I will be honest and say i have not had any DPF issues on this car and it is about to roll over 150k, i put it down to daily motorway driving and the fact i drive it hard so everything gets nice and hot. I have had the swirl flap bar that moves the flaps in the intake pop off - To be honest i just bought a new bar and its been on ever since. One thing worth remembering - when topping the oil up i tend to fill it to about halfway between Min and max - this way when it regens the DPF is any fuel gets into the sump it wont push it over the max

[@leedsdashcamnetwork9577]

samuelellisuk no probs... got the car back yesterday... full service and intake and egr fully cleared.. had to have dpf cleared out also. the pics showed something just as gunked as yours if not more. car feels much more Powerful now that it's breathing better. where did you get swirl flap rod/bar from? cheers for replying.. as I rolled out the garage... Speedo rolled onto 188,888 miles..😜

[@1990JohnG]

IS there a chance you could do a guide on removing the valve cover? or is it ok to just go ahead and undo the fuel pipes, pressume theyre under pressure i dont know? Also great guide, i'll be looking to do this shortly.

[@yanjungblutscota7779]

Mate, mine has 170 thousand k and was never cleaned .... the car is shaking a bit on low Rpms:.. you think I should do that service ??

[@gasgas2689]

It would appear that when Summer 2021 eventually arrives I will be spending a week cleaning loads of carbon from inside my D5, removing flapper flaps - I had better not watch any more V5 videos or the list of jobs will take me into next winter. Thank you.

[@MervinSkidmore]

Thanks great content, Put my mind at rest after finding a similar situation today on my 2007 V70 d5.... So bad in fact the DPF was solid.. Went the extra mile on mine & removed the inlet manifold swirl flaps were spheres of carbon! - EGR valves are the work of the devil (Basically its like farting in bed & putting your head under the covers!!!) - Waiting for parts at the mo, but happier now i know its not just mine - there all like it, - any thoughts on mapping out the EGR ? Thanks Again - Steve.

[@rablark268]

How difficult is it to remove the inlet manifold , i would prefer to do this too.

[@MervinSkidmore]

@@rablark268 Not terrible, But the injectors need to come out - If one sticks be prepared to replace it, soak the night before with release "schmoo" (wd etc) and be prepared for wallet rape if you need a new egr ! - "Good Luck"

[@rablark268]

@@MervinSkidmore I'm looking into the best way to remove injectors now such as slide hammer tool off ebay etc. i'll soak them every day until i do the job too. I'm thinking my entire induction system on my D4 engined V50 needs de-gunked !

[@MervinSkidmore]

@@rablark268 Had to change one of my injectors - The slide hammer tool means removing the top of the injector - mine didnt survive that - My buddy made one that fits onto the fuel connector - works better but you have to be gentle as its not a direct pull - soak em and they "should" come out - Good Luck.... Steve.

[@chilithetalkinghusky5578]

would anyone suggest using a vacuum cleaner with disposable bag to do the cleaning?

[@barrybritcher]

Just use a second hand Dyson etc

[@robmus3085]

imagine how your swirl valves are looking

[@FGX318]

And you’re doing all this with a submariner on the wrist !! 🤪

[@samuelellisuk]

I wish that was my watch, those are my dads hands while I held the camera for those bits - he likes he watches

[@czarekmarczyk6783]

Nice video! I’ve got one question - do we have to remove whole egr valve or such cleaning as you’ve done is enough?

[@hermanmunster3358]

You can if you want to give it a meticulous thorough clean. Or just scrape out what you can with a spoon, then soak all areas with carb cleaner spray, and wipe out any remains with a rag, where you can reach. You could unbolt the throttle body from the right side of the egr and just let it hang over a takeaway food tray, which is what I did scrape out the thick of the crap, and just soak it with carb cleaner, and loosen the remainder with a toothbrush. Repeat until you get clean metal. Unbolting the throttle body gives you easier access to both sides of the egr, making cleaning it much easier.

[@MrChristo1985]

Would a terraclean not of rectified this ?

[@samuelellisuk]

A terraclean might have helped but i doubt that it would have removed as much as cleaning it manually

[@cameronhendry9680]

MrChristo1985 have to take the egr off these in order to terraclean, terraclean would move more carbon (marginally). Regular induction terraclean on these is advisable and will help the build up in the egr

[@MrChristo1985]

Cameron Hendry yeah m8 am gonna follow this video. Hopefully make her breath a bit easier

[@cameronhendry9680]

MrChristo1985 I got mine terracleaned (I work for a terraclean agents) now I just do what he done every now and then and it's spot on. See what your inlet manifold is like, mine is choked up really badly

[@jimpoyntz8473]

Having done a few D5's now I wouldn't advise carb cleaner. Far cheaper and a far better job with Mr. M*sc*e Oven Cleaner. Contrary to popular belief, it DOES NOT melt aluminium but makes short shift of carbon. Last 2.4D I took the injectors out and the top off and did the whole bloody lot even below the swirl valves. Trust me, what you see at the EGR is the same at the swirl valves. You need an old wet & dry vac to do the top as you don't want that stuff heading for the combustion chambers. A day at least perhaps a day and a half. Cost for cleaner, injector seals, clamp bolts was under £50. Don't buy injector kits at £30-35 a pop as Volvo will sell you the seals and the clamp bolts separately. I used the original top gasket and injector clamps and no leaks anywhere.

[@icandoitycandoit613]

Hi! Great vid by the way. I was thinking about doing the same to my car but lets say if i wanted to remove the whole egr to i need to drain the cooling system? Read this somewhere else...

[@murraystorm6392]

I have to point out that anyone doing this job really really really needs to wears gloves, the contents of your EGR valve pipework are not only nasty, dirty but also CARCINOGENIC!!! :o

[@samuelellisuk]

+Murray Storm Yep - as you said the stuff that was removed you really do not want on your hands, if i was doing it again i would have worn gloves but i simply forgot until i was at the point where it was already on my hands

[@petethompson1282]

only if you do it day in day out. Once for an hour wont bloody hurt.

[@pwood5733]

“If ya gonna do a job ya might aswell do it right”. I bet ya dad told ya that 😊

[@tuxnor]

Good vid thanks ,, get in get dirty :)

[@LaddieT]

Just did mine, same car, Euro4 with similar mileage. Good lord, all I can say is wear gloves! I had dirty hands for a week!

[@samuelellisuk]

Yep, both me and my dad had stained hands due to this but it was worth it

[@mehmettks3969]

Thanks for your movie but i don't understand what u say.have a good day

[@ИванШереметев-щ3л]

Снимите его с двс и промойте как следует! Но судя по нагару там не лазили никогда!

[@isayilmaz1969]

,🙏🙏🙏👍🌷

[@roadwraith6]

I would use a old vacuum cleaner when I would scrape lose they carbon

[@samuelellisuk]

Yes I agree, it is something we were going to do but we decided at the last minute to collect as much as we can just to see how blocked it was

[@roadwraith6]

samuelellisuk ah didn't think of that. good to see. but I get paranoid about my D4. how man km have this car done. my have done 120000km so probobly have alot of carbon to :-S

[@doogie1350]

sweet fucking jesus

[@insidebyte8561]

Poor fuel and oil quality causes it to be that bad :/

[@cretz2471]

why not take it off and just use brake cleaner its the best then let it rest in diesel or degreasing liquid

[@TheUltimate65]

Let det engine been realy hot, the dyuly driving of 10 minutes its not good fore engine , looks like the turbo leak oil from the senterbushing and the go the intercooler and into the intake, Not all thinking over what type of oil engine must have , a flush of the engine , and replement the oilfilter after the flush , emty the engine oil good before refill the oil and oilfilter 👍😁

[@gimmieliberty6514]

thanks for the vid, id be happy to do the spannering but the actual carbon cleaning is womans work

[@stuartmcgarrigle6610]

163 bhp. I own the same car. Mine is constantly in limp mode even tho internally its clean. Think the EGR motor is tired.