Volvo XC90 2.4 D5 Euro 4 EGR, Cooler & Throttle Body Removal Guide How To DIY

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3 жыл бұрын

How to remove the EGR, EGR Cooler and Throttle body on the Volvo XC90 2.4 D5 Euro 4 engine.
Intake Mainfold: • Volvo XC90 2.4 D5 Euro...
Swirl Flaps: • Volvo 2.4 D5 Swirl Fla...
Remove the engine cover.
Remove the intake pipe for the airbox by removing the 2 8mm bolts at the front and squeezing the other end out of the airbox.
On the later XC90 the ECU is on top of the airbox. You'll need to disconnect the wiring for the ECU so make sure the key is out of the ignition (and keep it out) or to be extra sure disconnect the battery in the boot: • Volvo XC90 MK1 Battery...
Undo the jubilee clip for the MAF sensor and disconnect the wiring, to the right of the airbox there is a nut attaching the airbox to the body of the car (it's been missing on every car I've worked on). There's also a vacuum valve on the front of the airbox you can slide off the clip. You can now remove the airbox.
Release the wiring harness from the side of the engine near the high pressure fuel pump and disconnect all the wiring for components nearby.
Undo the jubilee clip for the throttle body and then remove the 4 8mm bolt holding the throttle body on (don't lose the gasket).
Undo the pipe between the EGR and the intake manifold, this will be filthy so will benefit from a clean also.
Remove the high pressure fuel pipe above the EGR with 2 15mm nuts and then you'll also need to remove the bracket on top of the EGR with 8mm bolts.
Follow the cold air pip to the turbo where the MAF was removed and you'll see a 10mm bolt half way down. Also remove the jubilee clip and remove the pipe.
On the side of the engine above the EGR cooler there is a 10mm bolt holding the Cooler to the block.
Now you'll have a really awkward jubilee to remove from the gold pipe which is the feed from the exhaust to the EGR, I managed with a really small socket and ratchet. Unfortunately the brake pipes leaving the ABS unit make it nearly impossible to use a screwdriver. Even when loosened the clip may not allow the pipe to be removed so you may need to twist a screwdriver in the gap to loosen it fully.
Remove the clips on the coolant lines on the EGR cooler. You won't need to clamp them as you'll only lose the coolant that's physically inside the cooler.
Finally remove the 2 15mm bolts on the front of the EGR and you'll be able to manipulate the EGR and Cooler out of position.
To clean the EGR there are lots of methods on KZfaq, I tend to use a combination of Bojo scrapers, oven cleaner and even a steam cleaner when I have one handy.
Thank you for watching this video, I really hope it helps with your job.
These videos do take a lot of time to put together and often cost money in parts so I really appreciate the support I get when you like, subscribe and comment!

Пікірлер: 51

@davidm9090 3 жыл бұрын

Found this video right before doing this job and used it as a guide, very helpful! You allayed my main concern, which is how much water would come out of the cooler pipes (basiclaly none) Couple of points that may help others: 1) the EGR and cooler assembly comes out fine without removing the high pressure fuel line and bracket (and obviously it's better not to remove it, just in case) 2) The jubilee-style clip on the back of the cooler is actually a clamp that locks-in the flanged ends of the cooler and exhaust pipe, so it needs bending right back to separate the cooler from the exhaust. All the pulling and twisting in the world won't get it off, you have to bend it back then the two will literally fall apart (worth looking up a picture of this part to understand what you're up against!)

@anguspatterson9449 2 жыл бұрын

One of the best and concise videos on step by step instructions, absolutely brilliant thanks for showing this 😊

@IAMASPANNER 2 жыл бұрын

Thanks Angus, much appreciated!

@join811 2 ай бұрын

Thank you! Your video was very much spot on, with useful hints and explanations. Very well directed when ot comes to get the job done. Thanks again. 😊

@IAMASPANNER 2 ай бұрын

Thank you for the kind feedback, I’m very glad to have helped 😊

@izyfication Жыл бұрын

What a great video ! I will clean up my EGR and be use of your vidéo i am more relax 👍🏻🇫🇷

@IAMASPANNER Жыл бұрын

Thanks Jérôme, glad to help!

@ukgardener973 2 жыл бұрын

This is a fantastic video. I’m actually doing my xc90 and boy it’s also clogged bad!

@andrewnevermind4902 6 ай бұрын

I did mine in the summer. There was about an inch of smutz all the way round.

@hako2127 3 жыл бұрын

Waw! Great job man with one hand ! I have one but i can’t do that😂 Thanks for thé video

@IAMASPANNER 3 жыл бұрын

I much prefer having a camera man because I can do close ups much easier while working but this video didn’t seem to come out too bad thankfully!

@cdmChase1 2 жыл бұрын

Thanks man, used this to price a job up! 💯✌🏼

@IAMASPANNER 2 жыл бұрын

Glad to help!

@gunnars6173 2 жыл бұрын

This video saved me from taking my Volvo V70 III to the professionals. In my first attempt prior to to watching this video i got stuck in the process. To know that you don't need to drain the coolant is a great hint. And to know how the V-Clamp at the back of the EGR Cooler works makes this repair attempt a success or a failure. I found it very useful to unscrew this clamp almost as much as possibe. But that will not loosen it from the pipe sufficiently. you really need to get a big and stable screwdriver and pry it outwards. Once you have lifted it in one position it gets very easy. Its also important to have a good open position for that clamp when you reconnect the pipes.

@IAMASPANNER 2 жыл бұрын

100% agree about the V-clamp. When I first did this job on my V70 I didn’t manage the get that clamp back on properly, they’re a tricky one and it’s a real stretch getting down there to reach it. Glad you got the job done and saved some money!

@gunnarschroder7505 2 жыл бұрын

@@IAMASPANNER what made it a lot easier for me to reach down to the V-clamp and the egr cooler connections was removing the battery box. It was a bit tricky as two of the 4 screws were really rusty but once the box is out you gain a lot of space so its so much easier so work down there. Would recommend this step to everybody doing this job on a v70 III

@IAMASPANNER 2 жыл бұрын

@@gunnarschroder7505 oh I haven’t had a P3 V70 so didn’t know they moved the battery out of the boot. That’ll be the same on the C30, S40 and V50 then, thanks for sharing.

@A-S-concept974 2 жыл бұрын

Good job👍

@einarolsen7852 2 жыл бұрын

thank you so much, this was a very good video, very helpful, thanks:)

@IAMASPANNER 2 жыл бұрын

You’re welcome Einar, thanks for the comment!

@ukgardener973 3 жыл бұрын

Thanks for sharing!

@IAMASPANNER 3 жыл бұрын

Thanks for watching!

@cptfrecell 3 жыл бұрын

Nice

@skidillydiddily8571 3 жыл бұрын

Just done this job on a V70, hardest part was reconnecting the exhaust feed pipe to the egr cooler, absolute pig of a job when you can barely get one hand to it!!

@IAMASPANNER 3 жыл бұрын

I agree completely, and once you have it on it takes some tightening, this one leaked for a bit before tightening a lot more!

@skidillydiddily8571 3 жыл бұрын

@@IAMASPANNER I was ready to admit defeat with this then my dad said try using a bit of tubing which was a snug sliding fit in the cooler & the exhaust flexy pipe to keep them in line while doing up the clamp, it worked!!

@barbuta60 Жыл бұрын

Good job. Thanks!

@IAMASPANNER Жыл бұрын

Thanks Viorel 👍

@bashy2.0 Жыл бұрын

Hi, thanks for the video, will this help my issue, when at idle and put my foot on the brake, the revs drop, its quite noticeable? thank you.

@emmaorion 3 жыл бұрын

Just started this on my 2008 XC70 D5. Only main differenc I see, is the wiring harnes infront and on thebside of engine/egr. Currently steuggeling with an 8mm bolt on the throttlebody that also holds a wiringclamp.

@IAMASPANNER 3 жыл бұрын

Hope you got sorted Marius!

@emmaorion 3 жыл бұрын

I did, in the end! Holy crap wjat a journey I had with this repair. It started when the i got an error in the display saying DPF is full. I asked a friend about it, he said it cpuød be the egr acting up. So, I took it for a diagnostic and it had an error on the DPF sensor. Diagnoatic also revield that DPF was not full. So, I tore off the EGR, and cleaned it. While I was at it, I also removed the inletmanifold and cleaned it. Also replaced the DPF sensor. Hoping this would sort it, I went for a new diagnostic and reset. Same error. But now, with the new sensor, readings were skyhigh. So I suspected a broken wire. Luckily theres only about 5000 wires , twisted around each other, in the harness 🤣🙈 Eventually, i found the broken wire, replaced it, retaped the harness as tight as I dared, and the car runs better then ever before! But damn... Next time I'll do the easy part first 🍺

@IAMASPANNER 3 жыл бұрын

@@emmaorion well done though, wire breaks are often notoriously difficult to find, one of my worst nightmares! Glad you got sorted and hope it runs well for a long time now 😁

@kevinrobertson3513 Жыл бұрын

Hey, what did you use to fix the cooler clamp back on?

@kdillon5358 3 жыл бұрын

Hi great video. Is a 2010 Volvo XC90 2.4 d5 a good used buy ?

@IAMASPANNER 3 жыл бұрын

With a good service history, yes definitely!

@rembaror4035 3 жыл бұрын

when you cleaned it all what was the difference in the engine can you explain if it made a big differrence

@IAMASPANNER 3 жыл бұрын

Hi Remigia, this particular car was experiencing several issues already with a bad smoking issue and rough idle. It took a few days afterwards to resolve noticeably but it did eventually seem to do the trick. I’ve done this job on several cars and the amount of carbon buildup definitely chokes the engine, I’d say removal makes them more responsive and smooth running but even if it doesn’t it just feels good to know it’s clean and not going to block up completely preventing future issues. Hope this helps!

@pekostanojevic95 3 жыл бұрын

Mine has some white or grey smoke..will it get any better if i clean it?

@IAMASPANNER 3 жыл бұрын

White smoke could be water in the exhaust so I’m not sure this would help, it’s a good job to do regardless though as it will improve the running of the car.

@arlindleci 2 жыл бұрын

Removing these does affect black smoke when accelerating hard, or smth in engine?

@IAMASPANNER 2 жыл бұрын

Cleaning them can help with all running issues as they get very clogged up after 100k miles.

@mamadidikgale6435 2 жыл бұрын

My 2006 Xc90 euro4 D5 has black smoke on idling and it doesn't boost at all. It's really depressing me 🙁😞. OBD says DPF faulty but even when I change sensors it remains the same

@IAMASPANNER 2 жыл бұрын

What mileage are you on? There’s every chance the DPF is genuinely faulty. You could try having it removed and cleaned though.

@khansterkhan2258 Жыл бұрын

I Cant Find the Throttle Body xc90 2.4 D5 help help help

@alouisschafer7212 Жыл бұрын

What happens if you just leave the EGR Valve unplugged? Any Codes or Limp Mode?

@IAMASPANNER Жыл бұрын

Codes definitely and limp mode most likely.

@user-gk5fb8zx1n 2 жыл бұрын

do you have any experience with removing the EGR completely from the car and Blanking it off?

@IAMASPANNER 2 жыл бұрын

I’ve never blanked off an EGR on my cars, sorry.

@alperraim1385 2 жыл бұрын

What were the symptoms on the car, thanks

@IAMASPANNER 2 жыл бұрын

Very smelly smoke and rough idle as far as I can remember. This helped but the thing that made the most difference was changing the swirl flaps. Regardless of symptoms doing this job will help any car run better.