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Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

This is aimed at owners of Volvos with the new D4 VEA diesel engine. There seems to be a common problem which affects the engine's exhaust gas recycling (EGR) function.

Several owners of new-ish Volvo S/V60 and XC60 cars with the VEA D4 engine have had the ‘check engine’ light pop up within a few months from new (reported on the Volvo Owner’s Club forums).

It happened to my own V60 D4 (registered July 2014, 5,900 miles from new) this morning on the way to work. Engine behaviour was unchanged, and there was no information message in the dashboard display.

I called the Volvo main dealer which supplied the car and straight away the service manager told me that it's a known problem with the engine’s EGR valve and cooler, they will order new parts from the factory and will let me know when they have them in for fitting.

What surprised me was that they didn't ask me to bring the car in to have the diagnostic fault codes read, or ask me about any other symptoms – they just said yes, we know what the fault is, and they're going to throw the new EGR and cooler at it. The service manager went on to tell me that they did three such repairs yesterday on D4-engined cars, and have parts on order for another seven cars too.

From this, it seems the problem is fairly common and widespread in cars with the D4 engine. It also seems to me (although this is purely my opinion) that the replacement parts are a revision or update of the factory-fitted parts.

The dealer did state the car is safe to drive in the meantime, and that if I should experience any further issues (such as the engine going into limp mode), I should simply call Volvo Assist.

If I find any further infomation, I’ll post it here.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - adnuloy

Hello,

Here is my experience on this same issue.

I had it with my XC60 with the new D4 engine, only at around 3700 km mileage. I was also told by the service (in Luxembourg) that the EGR was partially clogged hampering the movement of the valve. Apparently, it is quite a common problem on the new D4 engines. They have been receiving plenty of similar calls lately.

They did two things to fix the problem. First, they have made an update of the software on the car. Secondly, they replaced the EGR with a newly designed (or revised) model, ordered directly from Sweden (that is, not from the stock).

They told that they have been in contact with the Volvo HQ all the way through. The service did only what Volvo instructed them to do. This makes me think that Volvo is aware of the problem and have made fixes in the software and the EGR model.

It is very frustrating to have such a head-ache at such an early mileage. I really hope the new EGR will solve the problem. I do not want to have the same thing over and over every 4000 km.

I hope this helps.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

Thanks for that -- yes, Volvo HQ is distributing updated EGR valves and EGR coolers to dealers, so these can be fitted if a customer's car gets the 'check engine' light. I don't think it is a full recall as yet, but Volvo is gearing up to fix the problem.

Mine is booked in for a valve replacement in the next few days.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

An update on this issue -- Volvo seems to be replacing the EGR valve and cooler on every VEA D4 diesel, either when the owner reports the problem or at a scheduled service as a matter of routine.

The problem seems to be that the original factory-fitted EGR cooler unit had sealing problems, allowing small amounts of engine coolant to mix with the exhaust gases in the EGR valve body. Over a few months this was making a coolant/soot paste which eventually causes the valve to stick.

Volvo is now fitting updated EGR valves and coolers.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Blackbird63

I have this problem which has been ongoing since the 17th Feb, hopefully the new EGR cooler with be with my dealer on the 8th April.

My concern is with the EGR valve not working correctly, blocking the cooler for nearly 2 months and 1200 miles what damage has been done to the mechanics of the car, i.e. catalytic converter. I asked Volvo and they said that if the was likelihood of damage being done I would have been informed and given a courtesy car. What’s the consensus on this from trained mechanics?

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

The general feeling on the Volvo forums is that it won't damage the motor. The EGR valve's purpose is to minimise NOx emissions, it's not critical to the engine's operation.

Exhaust gas is usually only recycled at very light throttle / low rpm - if the engine is doing any serious work then the EGR valve shuts to stop the exhaust being recycled.

Also, when the DPF is regenerating in any modern car, the EGR valve also shuts, to raise exhaust gas temps to the required regeneration temperature.

The sticking EGR valve won't have harmed the engine.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - jifen

Same issue with V40 D4 VEA. New EGR valve and Cooler fitted Mach 2015 @ 6,000 miles (cooler was 90% blocked with tar like soot)

Apparently since mine was done Volvo's latest 'fix' is merely to load a revised engine managment map.

I currenlty have an open complaint case with Volvo as (in my opinion) this new map has completely backed off the small turbo so I no longer have a car with instant torque, I now have a car which only comes awake above 2k revs. Car has been verified as having no faults and the perfomance change came with the new map.

Have also driven an 'off the production line' March 2014 D4 and it was exactly the same as mine now is.

Not a happy bunny - nor am I happy that after over 5 weeks of complaint I still have no answers whatsoever as to if they consider this the 'permanent solution', since this is no longer the car I bought! A car I was formerly head over heels in love with and made me grin every time I drove it

Edited by jifen on 11/05/2015 at 18:02

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - EllisG

I had the EGR valve replaced back at the end of Jan 2015 but have noted that my average MPG has gone from about 40 to 33.

Could this really be caused by a replacement EGR valve? Performance hasnt seemed to of changed either.

Local dealership not interested either :(

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - DRT05

Did you get any ositive outcome on this?

My car is doing wxcatly the same following a EGR valve replacement.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Myladyliz

Tonight my 64 reg S60 D4 shuddered for the same reason. 11111 miles. Lets see what TMS Volvo have to say tommorow morning. Why warn't this replaced in the august service if it was a known problem at Volvo HQ ?

Edited by Myladyliz on 01/12/2015 at 22:43

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - John-M

Same problem with engine check light at 8000miles. Engine went into limp mode as I was driving to the garage to get EGR valve changed

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SCB270267
Just thought I would add my own experience with my XC60. EGR Valve & Cooler replaced and engine software updated in March 2015 at about 6000 miles. Back the dealership just now to have the EGR Valve and Cooler replaced again (13000 miles). Been advised that this an ongoing issue that Volvo are working on so not sure if this is the solution or just an interim fix.
I can't say the performance has been affected since the software update but definitely think the fuel consumption has increased.
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - ajg23698
This is my experience with the D4 engine egr problem.
Car purchased April 2014. Check engine light first displayed March 2015 at ~7000 miles. However I had already picked up that my mileage was dropping alarmingly (from ~49mpg to ~40mpg). Valve was ordered from Sweden and I was informed that it was ok to drive the car in the meantime. It took ~3 weeks for valve to arrive and 2 days to fit! Cooler was also replaced and new software downloaded. January 16 at ~13000 miles check engine light up again. I had noticed that my mileage had fallen away again during December. Under Volvo's instruction only the cooler was replaced and new software downloaded. Before I reached home (12 miles) the check engine light was on again! Car returned and valve and cooler replaced with more new software downloaded, a further 2 days lost.
No-one seems to be surprised and no-one is able to give any assurance that this is a permanent fix.
Whilst there's a great inconvenience caused by this, as it is under warranty, I am not paying for these repairs. However I have to look at the time when it is no longer in warranty.
These repairs will be expensive!
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

There's still no 'permanent' fix as yet. Many owners are on their second or third replacement EGR valve / cooler.

The current situation is this, as relayed to me by the dealer service manager at my supplying Volvo main dealer:

Volvo HQ in Sweden sent technicians to the UK in November 2015 to set up live data-logging on a selection of cars exhibiting the EGR fault. My own car was shortlisted for this datalogging, but in the end they chose cars that had actually gone into limp mode with the fault (mine never has).

This testing concludes on 1st February, after which they expect to have a permanent fix prepared. So the official advice seems to be:

1) If a car has the 'Check Engine' light but still drives normally, leave it for now until the permanent fix is available.

2) If a car does go into limp mode with the EGR problem, fix it immediately with the currently-available stock of updated EGR valves and coolers - although this is NOT regarded as the definitive, permanent fix.

My own personal conclusion from this is that Volvo has realised it can't carry on just chucking new parts (plus all the labour costs etc) at affected cars, in the hope that it fixes them. Instead, they are now only applying the interim fix on an absolute 'as-needed' basis, and waiting for a permanent fix based on the data from the live logs.

My own V60 D4 is due for its second replacement cooler - the first was done in February 2015 at 7,000 miles, I've now done 17,000 and the Check Engine Light has been on since November.

Luckily, it hasn't affected economy or performance on my car, nor has it ever gone into limp mode, which some cars do.

Volvo is VERY lucky that more cars are not going into limp mode with this fault. From the Volvo UK Owners Club forums, this issue is affecting a majority of D4 VEA engined cars.

It's a shame because in all other respects, it's a great engine. I really hope, for Volvo's sake, that they have not rushed the introduction of the VEA motor. If you're going to bet the company's future on a brand-new engine, you need to be pretty confident that you've got the wrinkles ironed out.

Or have all the car manufacturers forgotten NSU's RO80?

PS - before anyone even THINKS of mentioning 'premium diesel', there is a large number of owners that have never used anything other than premium diesel from brand new. It has not delayed or prevented EGR problems.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - newcastleman

Just had my EGR cooler replaced at 10months/9000 old. Was told no EGR valve replacement or Software update. The car, a V60 manual, was delivered from factory March 2015 and I was told then it had all the latest fixes.

As the D4engine is now 2 years old anyone know what Volvo's attitude will be to out of 3 year warranty claims in this area?

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

Just had my EGR cooler replaced at 10months/9000 old. Was told no EGR valve replacement or Software update. The car, a V60 manual, was delivered from factory March 2015 and I was told then it had all the latest fixes.

As the D4 engine is now 2 years old anyone know what Volvo's attitude will be to out of 3 year warranty claims in this area?

On the Volvo owners' forum, several owners have had communication from Volvo UK stating that the company will continue to support EGR-related problems after the 3-year warranty has expired.

The company is trying hard to sort the problem out, but as I said above they've avoided disaster by the skin of their teeth with this issue.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

An update to this saga. Volvo now believes it has the definitive fix for the EGR problem which will soon be available, apparently.

Short version: It transpires that the problem is being blamed on OVERcooling of the exhaust gas in the EGR cooler, to make the car meet Euro 6 emissions standards, and the pipework in the EGR cooler being a bit too small, therefore blocking up too easily.

New EGR coolers are being manufactured and will be fitted to affected cars. It's not yet known if they will also be retro-fitted to all cars during routine servicing.

Long version: Volvo decided to use advanced EGR cooling instead of AdBlue to meet the Euro 6 standard on the VEA diesels. To do this, it equipped the engines with a watercooled EGR cooler and a 'smart' coolant system, all controlled by the ECU.

Unfortunately, the serpentine S-shaped pipe in the EGR cooler that the exhaust gas passes through while being cooled, was a bit narrow in the original coolers, and the ECU was also keeping the cooler a bit too cool.

This led to condensation build-up inside the exhaust-gas passages, which mixed with the soot and traces of unburnt diesel in the exhaust gas to form a nasty paste which would clog up the passages over the course of a few months (the exhaust gas for recycling is taken BEFORE the DPF, so is both sooty and will have unburnt diesel from DPF regenerations).

Cars used for short trips would clog up within 6 months and a few thousand miles; cars used for mainly motorway miles would go perhaps a year and 20,000 miles or so, but eventually, the build-up of gunk would block the cooler. The use of premium diesel has made no real difference.

Volvo has revised the EGR cooler several times, and according to a head mechanic at a Volvo main dealer, they now have a version they are confident will not clog up. Volvo has also revised the ECU code controlling the 'smart' cooling system to, er, allow the EGR cooler to get hotter to stop the condensation build-up.

So let's see if it really does fix the issue.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Gabriel Campbell

hi ... tnx for the update ...

i am taking my XC60 in next monday ... same issue. However they said they will clean EGR and replace cooler+hosing only.

Do you have any update if the Volvo solution is permanent this time ?

-> www.volvoforums.org.uk/showthread.php?p=2202244#po...4

Do you have any images or part numbers/revision numbers so that i can confirm if the local dealer in malta will be employing a permanent fix ?

Also should the actual EGR be replaced ? has its lifetime not been compromised (electric motor stress ) ?

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Avant

Let's move this to motoring for a wider audience: I should have done this before.

I have a V60 D4 on order. The service manager at Yeovil Volvo acknowledged the problem, and like your dealer, says that Volvo now have a fix and that new cars will have the revised parts fitted. Let's hope!

Interestingly, HJ told me that the chief design engineer (I think that was his role) at Volvo had told him that the D4 engine was designed to run on premium diesel such as V-Power. (I don't think that's meant to imply that the EGR problem wouldn't have happened to cars using premium diesel.)

Edited by Avant on 15/04/2016 at 11:30

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

Let's move this to motoring for a wider audience: I should have done this before.

I have a V60 D4 on order. The service manager at Yeovil Volvo acknowledged the problem, and like your dealer, says that Volvo now have a fix and that new cars will have the revised parts fitted. Let's hope!

Interestingly, HJ told me that the chief design engineer (I think that was his role) at Volvo had told him that the D4 engine was designed to run on premium diesel such as V-Power. (I don't think that's meant to imply that the EGR problem wouldn't have happened to cars using premium diesel.)

Hi Avant, the technical source on the Volvo forum (a head mechanic at a dealer who has been tremendously helpful) says that Volvo is prioritising the new EGR coolers etc for cars on the production line, and then making it available to all affected cars.

Several owners on the forums run their cars exclusively on premium diesel and have still had EGR replacement: the problem is inadequate design / testing of the EGR function rather than choice of fuel.

The V60 package really suits me, and the D4 VEA is an excellent engine in all other respects - it's (slightly) more economical than its 5-cylinder predecessors, while giving better top-end power AND low / mid-range response. The only thing it lacks is the characterful 5-pot growl. Apart from the EGR problem, it seems reliable too.

I'd like to stay with Volvo when my current lease is up, but the latest plug-in hybrid options in the Passat and 3-series may well tempt me away as they are so much cheaper in terms of BIK tax.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - RT

Interestingly, HJ told me that the chief design engineer (I think that was his role) at Volvo had told him that the D4 engine was designed to run on premium diesel such as V-Power. (I don't think that's meant to imply that the EGR problem wouldn't have happened to cars using premium diesel.)

I thought there was a requirement within the EU that diesels are tested using ordinary EN590 diesel, ie the minimum standard

Edited by RT on 15/04/2016 at 12:11

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - focussed

If thse engines were devloped and tested in Sweden it's likely they running on swedish-sourced fuel which is likely to be different to the rest of europe.

Read all about it here en.wikipedia.org/wiki/Ultra-low-sulfur_diesel

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - RT

If thse engines were devloped and tested in Sweden it's likely they running on swedish-sourced fuel which is likely to be different to the rest of europe.

Read all about it here en.wikipedia.org/wiki/Ultra-low-sulfur_diesel

It happens, it's inevitable - BMW famously testing engines with Nikasil cylinder liners using German fuel and then experiencing many issues in the UK although both fuel sources met/meet the EU standard.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Mahiho
I have an xc60 d4 (2014 model) and just yesterday had the 4th egr valve on the car!

Looking to complain to volvo. Has anyone else done this and what was the result? Really hacked off that for 2 years out of my 3 year warranty the car has had to go in so many times!
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

On the Volvo forums, one owner successfully returned his car to the supplying lease company because of repeated EGR problems.

However, Volvo's line with all complaints around the EGR problems is 'this is what the warranty is for'. Some owners have asked for reassurance that Volvo UK will effect repairs on EGR problems for free AFTER the 3-year warranty has expired. Volvo UK has replied to these owners saying it will look favourably on such cases ... but it remains to be seen what actually will happen.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Gabriel Campbell

i am taking my XC60 in next monday ... same issue. However they said they will clean EGR and replace cooler+hosing only.

Any update if the Volvo solution is permanent this time and how to confirm/identify if my local dealer uses the latest/correct replacment parts ??

-> www.volvoforums.org.uk/showthread.php?p=2202244#po...4

Do you have any images or part numbers/revision numbers so that i can confirm if the local dealer in malta will be employing a permanent fix ?

Also should the actual EGR be replaced ? has its lifetime not been compromised (electric motor stress ) ?

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - DRT05

Ok so my EGR cooling system was repaced back in August last year. Since then my MPG has gone down. I had monitored this very closely and it had been around 600 miles per tank over two years. It's now 520 miles which is a massive drop. Any advice on what to do? Anyone had this resolved by Volvo?

Also my warranty expeires in the Summer of this year. Have Volvo agreed to cover any further replacemnets of the ECG cooling system beyond the warranty?

Any advice on who i need to inform?

Thanks

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

Ok so my EGR cooling system was repaced back in August last year. Since then my MPG has gone down. I had monitored this very closely and it had been around 600 miles per tank over two years. It's now 520 miles which is a massive drop. Any advice on what to do? Anyone had this resolved by Volvo?

Also my warranty expeires in the Summer of this year. Have Volvo agreed to cover any further replacemnets of the ECG cooling system beyond the warranty?

I'm on my third 'fix' for the problem (V60 D4 manual) in 27,000 miles, none of the fixes has affected economy and the wider experience on the Volvo forums is the same - it hasn't affected consumption for the majority of owners.

I think you'd have to contact your supplying dealer re. a warranty issue, as far as I know Volvo has not made any official announcements on this.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - DRT05

Thanks for response. When was the last EGR realcemnet for you?

Were any of yours replaced beyond warranty cover and if so did Volvo cover cost?

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

My most recent 'fix' was done in December 2016. The car's still in warranty and will be going back at the end of three years, as it's a company car.

This time Volvo didn't replace the EGR valve or cooler, but re-routed the coolant plumbing to the cooler and did a software update.

Volvo discovered that the EGR coolers were actually OVERcooling, causing condensation build-up which mixed with the exhaust gas to make a sticky goop that eventually bungs up the valves.

No-one yet knows what Volvo is going to do about extending warranty cover on affected D4-engined cars. I'd be tempted to have a stern word with your supplying dealer about it.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Davester

I bought a used D4 V40 in January, the Volvo 3-year warrantly ran out in March, but the dealer gave me 6 months... To the week of it expiring... this light comes on! It only has 41000 on the clock.

Has anybody had any success with Volvo repairing these? Is there an update on the parts yet - ie permanent fix?

I have tested the ECU using an OBDII scanner (Autel) and no error codes, and recorded a specific journey on it, then compared with a mates V40 D4 and it compares almost identically.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

Is yours definitely the D4 VEA (4 cylinder) engine? There's a chance yours may have the 5-cylinder 2.0 litre diesel which was also badged as a D4, and the 5-cylinder motors were NOT affected by EGR problems.

There is now a supposedly permanent fix. I would argue long and hard with the supplying dealer (assuming it was a Volvo dealer) that the EGR problem is known, and unless they can prove that your car has had the definitive fix (which was only made available in mid-2016), then they should check the car and do the permanent fix for free.

Without knowing the history of your car it's hard to know exactly what it needs, as the fix has evolved. If you did buy from a Volvo dealer, then I reckon you're well within your rights to demand to know what warranty work has been done prior to your ownership.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Kel75

Hi guys,

New to the forum. Bought a 64 reg XC60 with 35k on the clock in May, not from main dealer tho. Same problem as above happened to me recently. Is there any further details about a permanent fix?

Thanks in advance.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

New to the forum. Bought a 64 reg XC60 with 35k on the clock in May, not from main dealer tho. Same problem as above happened to me recently. Is there any further details about a permanent fix?

Thanks in advance.

Hi and welcome. There is a permanent fix that seems to be working so far. If your car has a full Volvo main dealer service history, there is a good chance of you being able to approach a Volvo dealer local to you and getting the fix done for free.

If the car has been serviced outside of the Volvo dealer network, then it's unlikely you'll get much, if any, goodwill from Volvo, I'm afraid. However, no harm in contacting the dealer and asking them, you should point out that you know it's a widespread problem.

No matter what any Volvo dealer may try and tell you, it is extremely common with the D4 4-cylinder diesel.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Ian999

Had my v70 d4 for 4.5 years from new and always had volvo dealer service. Has been back with EGR problems many times. Last EGR was replaced about 2 years ago. Engine light on again and diagnosed as needing new EGR cooler and pipes. Dealer says Volvo will not do under warranty due to age of car. Handed me a quote for just over £1000. Dealer admits new components may not solve problem in long term so i can expect same in a couple of years. Dealer also says that as volvo have not even now got a permamemt solution they have in some instances had to resort to replacing the engine. I have spoken directly with volvo uk and the dealer both acknowledge it is a known fault both now saying will not do under warranty. Disgraceful. I think I might be better cutting my losses and trading the car in. Very sad as i love the car EGR problems apart.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Avant

Probably no help to you, as no doubt your next car won't be a Volvo - but I had a V60 D4 new in May 2016 and I was told that that was one of a new batch where the problem was fixed.

I certainly had no EGR problems in the two years I had the car.

I do think it's a disgrace that a fault which is the same as one covered under warranty is no longer so.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

I have spoken directly with volvo uk and the dealer both acknowledge it is a known fault both now saying will not do under warranty. Disgraceful. I think I might be better cutting my losses and trading the car in. Very sad as i love the car EGR problems apart.

I'm sorry to hear that. Personally, I would go absolutely thermonuclear with Volvo UK (not the dealer) by email and phone: using choice phrases such as "I bought Volvo for its reputation for quality and safety, and you would agree that my experience has fallen a long way short of that", remind them of how many fixes you have had, and the fact that the latest fix has failed.

Keep at it, I've managed to get all sorts of out-of-warranty work done free on various marques just be being a disappointed customer. Don't get stroppy, just point out everything that's gone wrong and keep at it. Their default position is always 'no' - so keep pushing.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - ChrisFromFrance

Hello

I own a my 2014 V60 D4 181 HP. I have several EGR pipes, cooler, valves exchanges (in 2016, 2017..and need to be replaced since june 2018).

My car has now 120000kms.

Since the car passed 80000kms, the engine burns more and more engine oil, about 1 liter every 1300kms. No external leak.

It is over Volvo standard (0.5liter/1000kms).

My Expert (amicable procedure) detected cylinders leakage (from 20% to 60%).

Volvo wants me to pay for diagnose the engine (remove the breech) and it will cost about 2500€ to remove and replace the breech.

So it will cost me a lot.

It will be great if we could join how effort against Volvo company.

I'm close to start a juridical procedure but it will last a while (2 years?) and cost a lot.

Thank you.

Chris

my14 V60 D4 181HP Summum D4204T5 VEA Engine

Edited by ChrisFromFrance on 08/11/2018 at 22:00

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Beachman
Hello all,

Did I understand right, that the definitive fix for the EGR problem was released in the mid of year 2016? I have a year 2014 V70 D4 and EGR was fixed about month ago in 130 000 km (~80 000 miles). I don’t know if the EGR was fixed during the earlier owner already, but this fix was made in the official Volvo garage here in Finland. There are opinions that the newer fix of EGR won’t work either, but what I red from here, the mid 2016 version is working great? I quess I have that version now also.

Edited by Beachman on 08/11/2018 at 21:28

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Avant

That was certainly my experience with a May 2016 V60 D4 - no engine problems over, if I remember right, 26,000 miles in two years.

Assuming that the 'fix' has worked for cars from then on, I can't understand why Volvo haven't managed to apply it to cars made before then.

Edited by Avant on 08/11/2018 at 23:30

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - bazza

A friend of mine has a 65 reg D4 V40, she paid top money for what she thought would be a reliable car with a touch of comfort and prestige. Since she bought it, nearly new, it's had a completely rebuilt /replaced emissions EGR system under warranty, a new clutch box/cylinder etc, under warranty ( after total failure), and a recurring problem with over-heating rear brakes that the dealer will not accept as a problem at all.

It's a nice car when it's going, fast, refined, all those things but I certainly wouldn't buy one!

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Beachman
Hi

I haven’t had any problems since the EGR was fixed. I am just wondering has everyone great experiences about the EGR fix if it is made after that mid 2016. If it works in completely new cars, why not in repaired ones. It seems that people are just frustrated because this promblem is so common and they say that the newer fix won’t help either. But this forum was the first one where some one could tell about the final fix and it’s date (craig-pd130), so i’m still hoping that I have the latest fix and it’s working fine in future also. The D4 VEA engine is still so new (in a larger view) and Volvo has used about eight years to produce it before launch in 2014, so it would sound a suicide not fix the problem. People are used to drive over 300 000 miles (500 000 km) with Volvo engines, at least here in Finland :)

Edited by Beachman on 10/11/2018 at 11:06

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Magic Mike

Hey Guys,
I just had engine management light come up last week on MY15 v40 d4 which was diagnosed as an intake manifold fault.
They tried to charge me £750 but i contested and it was at the end done free of charge.
I picked the car thinking this is it until the next service but the car just feels very different. Turbo is not kicking in at all in low revs, engine sounds like it is strugling when accelerating and has developed new sounds, something i didnt hear before. It is just not the same car as beforr it had the repair done. Anyone else with EGR fault had this issue after the repair and was it resolved?

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130


I picked the car thinking this is it until the next service but the car just feels very different. Turbo is not kicking in at all in low revs, engine sounds like it is strugling when accelerating and has developed new sounds, something i didnt hear before. It is just not the same car as beforr it had the repair done. Anyone else with EGR fault had this issue after the repair and was it resolved?

Is yours definitely the 4-cylinder D4? It's possible you may have the 5-cylinder 2 litre diesel which was also badged as a D4.

In any case, the car should drive exactly the same after an EGR fix, but it doesn't sound like yours has had the EGR done if you were told it's an 'intake manifold fault'. Take it back to the garage and get them to look at it.

My guess is that they've not properly reconnected a vacuum pipe to a VNT actuator, or got them mixed up.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Magic Mike

Thanks Craig,

I am certain this is a 4 cylinder engine. Got it booked in for this wednesday, ill report back the findings here then. This is the 4th time in 9 months i am visiting the garage due to volvo design flaws.

I am also thinking they might have done the software update and remapped the engine to drop the performance and eliminate future clogg ups. It really feels like it is a totaly different car, it took me whole 2 minutes of driving to notice.

Thanks,

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

I am certain this is a 4 cylinder engine. Got it booked in for this wednesday, ill report back the findings here then. This is the 4th time in 9 months i am visiting the garage due to volvo design flaws.

I am also thinking they might have done the software update and remapped the engine to drop the performance and eliminate future clogg ups. It really feels like it is a totaly different car, it took me whole 2 minutes of driving to notice.

I had three fixes done on my 2014 V60 D4, none of them made any difference at all to performance or driveability, it was always good and strong. I'm betting the garage has not reassembled things correctly.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Smotters

I'm looking to buy a 2014/15 V60 D4 within the next couple of months and this ERG issue is putting me off. I won't have the luxury of finding an affordable one from a local Volvo dealer so I'm wondering how I can be sure that when I view one with, say, 100k miles on it, that I can know that the components have been upgraded. FSH these days just seems to consist of a load of stamps in the service schedule book; its becoming rare to get a full stack of bills. I expect I'll get a blank look if I ask an independent dealer if it's all sorted. And I'm guessing there's not the equivalent of a recall website where you can see if a vehicle has had official patches applied. Makes buying a D4 VEA vehicle a bit of a gamble :(

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - ChrisFromFrance

Hi

Here are my problems with my14 V60 2014/02 D4 181HP:

I have had several EGR pipes, cooler, valves exchanges (in 2016, 2017, the last one november 2018... the volvo dealer is persuaded that the prblem will come back!).

My car has now 128000kms.

Since the car passed 80000kms, the engine burns more and more engine oil, about 1 liter every 1300kms. No external leak.It is over Volvo standard (0.5liter/1000kms).

An official car expert has detected cylinders leakages (from 20% to 60%).

The only solution, change the engine, it will cost me a lot. Volvo doesn't want to participate. Or to add oil every 1300 kilometers....

So to be honest, look for an other brand!

Chris

my14 V60 D4 181HP Summum D4204T5 VEA Engine

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - sad face

Hi I am on my second XC60 full Volvo service history and low and behold at 65000 miles I got the engine warning light and a tortoise on the dash.!. I contacted my Volvo garage and they said "no problem we know what it is you need a new EGR,ITS COVERED BY THE WARRENTY just keep driving and we will order one in , I thought this only happened with low mileage cars? a bit worried but happy days. In it went got the swap back on the road a few weeks later the same lights, O SAID VOLVO bring it in, This time sad face "you need a new EMAP pipe this one has furred up unfortunately it is not covered by the warranty so that will be £170," "O said I seems a bit funny that ,may be its got something to do with the previous fault ", Don't think so sir but we will ask Volvo UK. Volvo UK say as a good will gesture we will do it for free, Back on the road again happy face.

Few weeks later its first MOT time sales through but now its out of warranty!!!!!!!

Month later the lights are back on

This is were it gets sad, in to garage, new engine 2 of the bores are cracked.!!

I have been told that initially Volvo will put 40% to the cost as another good will gesture.

Any body got any ideas if the previous faults could have contributed to the catastrophic failure of my otherwise bullet proof Volvo, I was looking forward to a new XC60 IN THE SUMMER.???????? (they don't build them like they used too )

Sad face.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

Any body got any ideas if the previous faults could have contributed to the catastrophic failure of my otherwise bullet proof Volvo, I was looking forward to a new XC60 IN THE SUMMER.

Sorry to hear about your troubles. Unfortunately I don't think the EGR-related problems will have caused the cracked cylinder bores. I no longer have a Volvo but I still visit the Volvo forum semi-regularly and while there are one or two cases of high oil consumption and related low cylinder compression (which may be related to a cracked bore), it's not yet a common problem, compared to the number of VEA motors in use.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - ChrisFromFrance

Any body got any ideas if the previous faults could have contributed to the catastrophic failure of my otherwise bullet proof Volvo, I was looking forward to a new XC60 IN THE SUMMER.

Sorry to hear about your troubles. Unfortunately I don't think the EGR-related problems will have caused the cracked cylinder bores. I no longer have a Volvo but I still visit the Volvo forum semi-regularly and while there are one or two cases of high oil consumption and related low cylinder compression (which may be related to a cracked bore), it's not yet a common problem, compared to the number of VEA motors in use.

For me, EGR problem and Oil consumption are linked.

EGR not fixed make lot of soots.
Soots come into the cylinder , soot + oil clog the piston rings.
Then piston rings become inefficients.
And then the motor burn oil.. and make more soots ...


Did the EGR clog the pistons or did the pistons fail and clog the EGR?

Edited by ChrisFromFrance on 20/02/2019 at 13:19

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Graham Taylor no relation
This is just a scandal. The EGR in this engine is rubbish and owners are being told to suck it up and cough up the cash. Warranty has not solved the problem and now some dealers are quietly passing on the problem to the next owner. VW and Volvo have a real problem with this equipment because it tried and failed to provide an emissions/ fuel efficiency solution. VW lied and came a cropper and Volvo appears to be going down the same route. If no one else has splashed this to the national media motoring correspondents then perhaps now is the time. I will contact a few and let you know if this will fly as a story. If people on this string are willing to talk to them and give them their stories then let me know and I will put you in touch. I have just been asked to cough £636 for a new EGR after spending £120 on a new air mass sensor. Had enough - time for Volvo to hold their hands up and save their reputation. (There is interest already - see city am here www.cityam.com/271109/volvo-facing-600m-hit-over-c...d
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SussexFactor
Absolutely gutted I have been totally satisfied with my 2014 2 litre diesel FWD XC60 bought from a reputable main Volvo dealership in Eastbourne East Sussex some two years ago, the car has lived up to my expectations until today. So car picked up for a service having previously rung the dealer service department as a amber warning light comes up which say simply, in the owner car manual it’s an emissions issue and told that’s fine unless it’s a red engine sign, so happily I carry on driving with no loss of power for the next week until service day arrives and a midday phone to say my EGR valve and cooler needs replacing at a discounted price of just over £1100 but thank god I found this site and forum, why on Earth are Volvo selling the D4 engine in various guises throughout the model range knowing quite well there is an inherent problem, the car is simply not fit for purpose and by now there should have been a recall, not just wait and see when it becomes a problem and lucky for some when it’s under the warranty. The car has been a real workhorse and a pleasure to drive it fits the bill and does what we need it do but for pity sake, Volvo need to get their head out of the sand, this is a time bomb situation and I feel deeply disappointed that with an iconic brand known for safety, dependability and reliability this is almost embarrassing failure to put right something that has been an engineering and design elephant in the room scenerio, you can not ignore this problem it’s a huge issue which will have a resonating effect and they know it, so it’s my mission now to take it up initially with the branch and then with Volvo direct, no way am I forking out over a grand only to pay for their mistakes, and if that does not work then it goes to the media and motoring journalists. Feel cheated and somewhat disappointed with not having previous knowledge of this consistent fault it certainly would have been one that I would have not chosen in a prestigious car which I believed had a pedigree of Volvos reputation.

Edited by SussexFactor on 01/03/2019 at 22:40

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Graham Taylor no relation
Good stuff Sussex Factor. I have paid for a new egr and got that check engine light after 2 miles of driving followed by the tortoise and reduced engine performance after 5 miles. Very sick. I will also be talking to Volvo and talking to some neighbours who are at the top of the automotive industry globally. I think we should follow up in parallel with the media and will be contacting them tomorrow. My email is grahammrtaylor@btinternet.com if you want to plan together.
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

Good luck both of you. As with any such endemic problem, having a full Volvo service history is a big help with this situation.

See also this 2000+ post thread about the issue on the Volvo forums for other owners' experiences: www.volvoforums.org.uk/showthread.php?t=221555

Bottom line is, if you've got a VEA diesel engine and it develops EGR problems, it should be a warranty / goodwill job. Every Volvo dealer knows about this issue, as every Volvo dealer will have handled dozens, if not hundreds of EGR valve / cooler replacements.

My own 2014 V60 D4 came from a large Volvo main dealer in Warrington, and I had 3 EGR coolers (all updated components supposed to give a definitive fix) and one new EGR valve during my ownership. I was told by the service team there that they were doing the fix on between 5 and 10 cars per WEEK from the start of 2015 onwards. A Volvo dealer who claims they don't know about the problem, or that it affects only a small percentage of VEA engines is, quite simply, lying through their teeth.

The EGR system as originally designed is fundamentally not up to the demands of real-world driving and meeting Euro VI standards, a fact which Volvo has now tacitly acknowledged by adopting AdBlue-based NOx reduction on the VEA engine (in line with most diesel engines from other manufacturers).

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SussexFactor
Tbh prepared to kick up a stink when we went into the branch, but spoke to manager and he is getting the new erg and the now final fix modification done through a goodwill gesture by Volvo, waiting on confirmation when car is going to be booked in to service department, so great result ,but will keep you updated

Edited by SussexFactor on 08/03/2019 at 21:04

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Graham Taylor no relation
Wow. Looks like a result. I have a Volvo trained mechanic going straight to Technical HQ at Volvo in the coming week. I will be using your experience to promote my case if that is ok with you. Let me know how you get on as soon as. Regards GT.
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - ChrisFromFrance

Hi

I'm from France and I have big issue with a V60 D4 181 my2014 volvo.

I have several EGR pipes, cooler, valves exchanges (in 2016, 2017, 2018).My car has now 131000kms. Full history Volvo.

Since the car passed 80000kms, the engine burns more and more engine oil, about 1 liter every 1300kms. No external leak. It is over Volvo standard (0.5liter/1000kms).

My Expert (amicable procedure) detected cylinders leakage (from 20% to 60%) depending of the cylinder. There are also leaks by the intake valves. Volvo asks me to remove the breech.

Volvo wants me to pay for diagnose the engine (remove the breech) and it will cost about 2500€ to remove and replace the breech.

So it will cost me a lot.

If you could help me it would be great.

my VIN number; YV1FW73CDE1198717

Thank you.

Chris

my14 V60 D4 181HP Summum D4204T5 VEA Engine

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SussexFactor
So the situation as it stands is two weeks ago we went into the branch and spoke to Joules the manager and explained the situation simply the XC 60 offered at an attractive price having looked at other SUVs from alternative manufacturers and dealers seemed the best option for my budget listed at 24K but given a promotional price of 23K, I used half of my Mother’s gift of inheritance and then to hell with it ! cashed in an ISA plan, so with our part exchanged Citroen C4 the deal was struck on a 9500 miles 2 year old perfect example and stunning Volvo. The manager was quite confident Volvo was likely to carry out the work replacing the EGR valve as a matter of goodwill, as quite rightly my opinion was you sold us a timebomb, knowing quite well the historic chance this component could fail, and following my subsequent research why on earth had this not been upgraded before we bought the Car in the first place, so bringing you upto date, we have been waiting for a response from Caffyns Eastbourne , but one week later I contacted the branch to see how things were progressing, this was handled by the general manager who’s comment was this, that it was the first he had known of the situation and he would discuss it in the branch managers meeting tomorrow and get back to us as soon as possible, but nothing has transpired, so as I write, I await Joules phone call to advise me what is exactly happening, was this a false promise of resolution and over stepped his position in command and his committed decision to put the situation in front of Volvos customer care and sort it out, I wait with for the phone to ring.

Edited by SussexFactor on 20/03/2019 at 10:48

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

@SussexFactor - you'll wait forever for a car dealer to call you when you want to BUY a car, let alone try and get some warranty work done. In my experience, nothing happens unless you chase them.

Edited by craig-pd130 on 20/03/2019 at 12:16

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SussexFactor
Hi Craig I have now had a response by the service manager who’s name is Mike, who says Volvo have agreed to a 70% discount on their prices, it still however leaves me with a bill of 62p short of £500 quid to pay for a inherent design fault, which I seem to be paying for their mistake and gamble as and when it would be a problem, it’s like there’s thousands of Volvo cars out there just fitted with either the D4/D5 series engines ( EGR valve/ cooler issue) and it’s simply a matter of time, a lottery as it could been seen, as to when eventually they will fail, so it could be a matter of a few months or a few years, my stance on this is that a product should be fit for purpose, and any failing part as a result of bad design or engineering no matter the window of time, unless tampered or unauthorised modification must and should always be the responsibility of the manufacturer and like the dealership, for they know the issue yet sell the product with the knowledge this exists, they will always be the first point of contact and as a trusted franchise need to honour and satisfy the customer regardless of who is negligent.
I am likely to copy this to Volvo customer services as unfortunate as it may be why should anyone have to endure financial loss as a result of corporate failure to address such as a major manufacturing fault from a leading European Car Brand, its outrageous and appalling forfeit of justice that the customer deserves better service and better loyalty.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130

@SussexFactor - exactly how old is your car? And it was definitely bought from a Volvo main dealer, and has always been serviced by a Volvo main dealer?

If you cannot honestly answer 'yes' to the last two questions, then 70% is a decent offer and I would take it.

But if you can honestly answer yes to those questions, then I would go absolutely thermonuclear with Volvo UK (not the dealer, but with Volvo UK customer services) by email and phone: using choice phrases such as "I bought Volvo for its reputation for quality and safety, and you would agree that my experience has fallen a long way short of that. I am extremely disappointed in this experience with my Volvo, especially considering that this is a highly publicised and well known fault with the D4 engine, and I expect better from such a trusted manufacturer, especially when I bought it as an approved Volvo used car with full service history, etc etc ...."

Keep at it, I've managed to get all sorts of out-of-warranty work done free on various marques by being a 'not angry, just very disappointed' customer. Don't get stroppy or insulting, just stick to the facts and keep at it. Their default position is always 'no' - so keep pushing.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SussexFactor
Morning Craig

Your absolutely right in the approach I should take and I will speak to them again, especially after the first contact at the branch from the now known identified service manager, gave the impression it would at all costs would be dealt with under a goodwill gesture by Volvo and was quite confident, giving the impression this problem was quite seen as normal protocol. So we believe the best thing is again relaxed but assertive meeting face to face with a manager and go for a 100% for exactly the reasons you mentioned and yes it has always had a full service history and bought directly as you say with Volvo assurance policy, with only a 3 month delay in servicing due to personal reasons and a unplanned trip abroad over Christmas, so we average about 9500 miles a year so having a strict yearly service is not a priority when the actual mileage they say between services is some 17000 miles.
Just to add I will give Caffyns the chance to review the situation and respond then contact Volvo direct customer services should the response not be a favourable.
We will see what happens, so watch this space as they say
Cheers Steve

Edited by SussexFactor on 22/03/2019 at 09:07

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Jon Gosling

V60 VEA D4, 72k miles, FVSH and just over 4 years old. A few days ago I had an almost complete loss of power that rendered the car undriveable, warning message ('reduced engine power') plus a tortoise symbol... I read the error codes using an ELM327 that I carry around with me and found a P2413. Car was recovered to a nearby Volvo dealer who confirmed that the EGR valve was stuck open and in need of replacement... during this replacement the EGR cooler was found to be partially blocked and deemed to be also in need of replacement (and apparently this had already been replaced once before!). Volvo goodwill covered 100% of the cooler, but only 50% of the valve, so I got a bill for £373 (included £60 for diagnostics).

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Avant

"....we average about 9500 miles a year so having a strict yearly service is not a priority when the actual mileage they say between services is some 17000 miles."

Be careful - when I had a V60 the service intervals were one year or 18,000 miles, whichever came first. A good system, and one where you know where you are. Preferable I think to intervals generated by a car's computer.

Maybe yours was different, Sussex Factor: but on the face of it Jon above seems to have got a better deal. Volvo should of course be making sure that all cars with full Volvo service history are treated consistently.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SussexFactor
Hi thank you for your comment and just to update although the dealership told my wife and myself there was no history that any previous work or issue with the EGR valve had been recorded, Volvo Head Office have since advised the car produced in 2014 recieved a new Valve and presumably cooler during the the following years 2015 and successive 2016, so presently in the hands of Volvo customer services and they are in talks with the Eastbourne dealership today Friday 29th March.
Feel disappointed there is an element of mistrust now in who exactly is telling the truth, don’t need smoke and mirrors, need the fault resolved once and for all and no cost to the end user meaning me the customer. Update due next week staying cool, polite and optimistic !

Edited by SussexFactor on 29/03/2019 at 15:38

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - craig-pd130
Hi thank you for your comment and just to update although the dealership told my wife and myself there was no history that any previous work or issue with the EGR valve had been recorded, Volvo Head Office have since advised the car produced in 2014 recieved a new Valve and presumably cooler during the the following years 2015 and successive 2016, so presently in the hands of Volvo customer services and they are in talks with the Eastbourne dealership today Friday 29th March.

Do you have the car currently? There's an easy way to check if it's ever had the latest updated EGR modifications. See this post here on the Volvo forums:

www.volvoforums.org.uk/showpost.php?p=2426426&...9

Bottom right of that picture you can see a hose about the thickness of a garden hose which has 2 jubilee worm-drive clips on it. That shows the engine has had what was supposed to be the 'definitive' Volvo EGR cooler fix (they re-routed the EGR coolant flow to keep the EGR cooler hotter, in an attempt to stop condensation).

Lift your bonnet and have a look (no need to remove engine cover). If your car has those clips, then the dealer is either barefaced lying, or incompetent.

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - ChrisFromFrance

It seems that there are 2 differents case on these VEA engines:

EGR valve should have been replaced once.

EGR Cooler:

1st case:
The engines with only the final EGR Cooler seem not suffering from oil consumption.


2nd case:
The engines with intermediate EGR cooler fix (2016) and then with the final EGR Cooler seem suffering from oil consumption.

Is this intermediate fix responsible of clogging intakes valves, piston rings ...

__________________
V60 my14 D4 181 HP VEA Summun Geartronic 8 speed

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SussexFactor
Ok this is the latest and hopefully the final entry, my Volvo was taken into the dealership some 6 weeks ago now, they had the car for about 8 working days and having stripped it down to the essential components such as EGR, cooler pipe that seemed to have had the infamous final fix indicator of two jubilee clips in place, and exhaust manifold sooted up cleaned and returned, but as a result they found the some inlet and exhaust valves were sticking and the tolerances were wrong ? So this warranted an actual bill of some £4000 as I was led to believe by the service department, however when Volvo UK were contacted, by the grace of God and with the goodwill gesture of the warranty management or customer services of Volvo my contribution was only part that being still a hefty £575. I conceded and accepted the deal without hesitation when consulting Quentin Wilson a friend of my late mothers and on his advice I simply went forward with the fix, and reluctantly but with satisfaction accepting his word rather than anymore stress, I said well let’s just get this done and put it behind us.
The car does seem better albeit a little sluggish on the pull away pick up speed, but having had a latest software upgrade/ update installed on the last service may find the difference in noise attributed to that alteration.
Message to self from now on, use Redex treatment every 10 to 12 weeks with a full tank of fuel, to ensure the DPF EGR is cleaned as simply I am not sure if using Shell specifically designed with cleaning solvent additives is cost effective or adequate, so that’s what I will do in the future, Redex and long fast motorway runs to dissipate the clogging up which seems to be the inherent problem with many modern day diesels, even when using Adblue on some models it’s simply a pain ! Whatever
Thanks all for your help along the way, I hope my experience may help others, just don’t trust the word of some dealerships, and try and do your homework before buying what could be a liability on four wheels.
Cheers Steve
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - SussexFactor
Hi see my latest update and hopefully this has been resolved for once and all, will be using a Redex additive in the fuel periodically from now on tbh
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Graham Taylor no relation
Graham Taylor no relation here again with some good news. I had my Volvo trained mechanic order an egr from a Volvo dealer. Engine check light and tortoise lights reignited after a couple of miles. So .... got my mechanic to ring the dealer and book the car (XC60 Dec 2014 D4) in. The car was fixed three days later. Volvo donated some £800 of parts for free and I just paid the labour. Amazing. Looks like a new engine. Many miles of pipes, rods, and notably a software update that only Volvo has. The problem I was told occurred only in the UK. CONDENSATION messes everything up. I am now a very happy bunny. EGRs can be fixed but I might go for hybrid or electric next time. The days of diesel are numbered.
Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Jon Gosling
Graham Taylor no relation here again with some good news. I had my Volvo trained mechanic order an egr from a Volvo dealer. Engine check light and tortoise lights reignited after a couple of miles. So .... got my mechanic to ring the dealer and book the car (XC60 Dec 2014 D4) in. The car was fixed three days later. Volvo donated some £800 of parts for free and I just paid the labour. Amazing. Looks like a new engine. Many miles of pipes, rods, and notably a software update that only Volvo has. The problem I was told occurred only in the UK. CONDENSATION messes everything up. I am now a very happy bunny. EGRs can be fixed but I might go for hybrid or electric next time. The days of diesel are numbered.

It sounds like your mechanic bought and fitted a replacement EGR valve, only to discover that the problem was actually a blocked cooler? For info, Volvo usually make a full 100% parts and labour contribution towards the cooler and a 50% contribution towards the valve. As posted above a couple of months ago, this was my recent experience, resulting in me paying 'only' £337 towards a total bill of around £1600.

Condensation occurs on the inside of the cooler and then mixes with the accumulated soot, this mixture then sets hard as it dries and eventually causes a solid blockage... this was worse on the original version as it was actually over-cooled (the revised cooler can be identified by where it connects into the engine coolant system, hence the need to fit revised pipework. I really can't see how this could be a UK-only problem and suggest that someone has got confused about the formation of the condensation being a weather-related external issue?

Volvo S60 / V60 / XC60 - Volvo D4 VEA engine - EGR problem - Big John
EGRs can be fixed but I might go for hybrid or electric next time.

However any recent car including hybrids that have and internal combustion engine will usually have some sort of EGR function - be it via a valve or variable timing

Edited by Big John on 29/05/2019 at 23:41

 

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