2014 XC60 has started to "stutter" in low revs.

[Paul230164]

Hi Guys, once again, thanks for all your help to date.

This weekend was dedicated to removal and clean of EGR. Actually, its quite a straght forward job and this video will certainly help with regard to process:

EGR Removal test and clean

You will need a Torx set up to T30. Incidentally, I used the acetone to clean rather than EGR/Carb cleaner. Glad I did not just have my nails painted

I did all this and it seems it was for no gain as it looks like its been cleaned and serviced recently. However, at least now I know its clean.

Moving on, I am going to look at Exhaust Pressure Sensor next. It really is the last thing in the process.

The car goes for new cambelt in a fortnights time. A Volvo specialist near me and priced really reasonably, £470 includes Original Volvo parts, water pump and auxiliary belt all done on a Saturday morning. I have mentioned this problem to him and he has offered diagnosis while the its in for Cam belt so fingers crossed he will find out what this car is doing.

Big thanks to Rxtian, appreciated mate. Will update as soon as the problem is found.

Paul

[Baffler]

Some further reading in Simeon90's thread that may be related to your issue: XC60 Auto - Jerky/kangaroo behaviour at low speeds

I posted some pics of the cracked intake pipe where unmetered air can throw out the various sensors.

[rxtian]

Fingers crossed you find the issue mate.

I had my EGR out yesterday, cleaning overnight and back in today. While the valve didn’t seem too bad, my cooler was pretty gnarly-expected that as it’s never suffered enough to get a replacement. I’ve attached some pics of before and after.

Jury is out on if it has improved my hesitation as it was infrequent so it will probably be at least a week before I’m confident. The Valve position seems to be following the desired very nicely now at least so that gives me hope!

[Baffler]

Similar cooler condition to my (2018) replacement cooler, rxtian, which was carried out under warranty to the best of my knowledge. The ultimate answer for these early VEA's is revised pistons and rings. The temporary (Volvo) fix is a revised EGR cooler, EGR valve plus a new cam cover and software updates to affected vehicles which now comes at great cost to potential owners if you don't have the ability to carry out the work yourself or have your main dealer defending your corner.

[Paul230164]

Originally Posted by Baffler

Some further reading in Simeon90's thread that may be related to your issue: XC60 Auto - Jerky/kangaroo behaviour at low speeds

I posted some pics of the cracked intake pipe where unmetered air can throw out the various sensors.

Thanks man, I did check to see if there were and splits, cracks tears in the pipework but in our case it all looks good. The whole issue is confusing because what ever it is thats wrong, is only wrong below 2000 rpm and up until the car is at normal running temp. Then it fixes itself. As I say, she is going in the specialist next Saturday so fingers crossed

[rxtian]

It’s amazing how exactly the same this sounds to mine!

I’ve done a 2 trips without noticeably stuttering since cleaning the EGR but don’t have faith it’s fixed yet. I’m looking at the live data and a bit surprised how much the EGR gets moved at low RPM, like it’s hunting.

I have noticed the idle has amazingly improved. I hadn’t considered it rough but now it’s literally imperceptible that the engine is on.

If it still stutters I’m thinking intake manifold clean is the next job… then EMAP and intake pressure sensors.

[Baffler]

Originally Posted by rxtian

If it still stutters I’m thinking intake manifold clean is the next job… then EMAP and intake pressure sensors.

And factor in the revised EGR cooler which, in my humble opinion, should be a direct swap for your old cooler at Volvo's expense.

[rxtian]

At the moment I’m confident the cooler isn’t the issue having just been cleaned and tested by blowing a shop vac through it.

I’m still suspicious of the EGR valve given it has a detent in the movement which I’m not 100% should be there.

But yes if it came to it, I would replace the cooler and valve as a set.

[Baffler]

Originally Posted by rxtian

At the moment I’m confident the cooler isn’t the issue having just been cleaned and tested by blowing a shop vac through it.

It may be clean/clear but I suspect any software update on our cars will be expecting the flow rate of the newer revised cooler. I'm speculating here.

Originally Posted by rxtian

I’m still suspicious of the EGR valve given it has a detent in the movement which I’m not 100% should be there.

In terms of design, having removed and thoroughly cleaned mine, it was relatively clean on inspection unlike other valve designs I seen but proved difficult to reassemble the motor to the housing and jammed if not 100% correctly aligned to the housing. Just double check it's correctly aligned to allow for free/flawless movement.

Originally Posted by rxtian

But yes if it came to it, I would replace the cooler and valve as a set.

We want revised piston and rings from Volvo...I have no problem servicing the various components after that.

[rxtian]

Did you take the valve apart, like the plunger away from the motor then?

The disassemble I did (EGR valve away frok the cooler but remaining as a unit) didn’t involve any alignment.

The revised software expecting a new cooler is a good possibility, thanks for the suggestion. I can’t remember for sure if the hesitation started around the time of the recall but I don’t think it did.

I understand the revised piston rings improve the oil consumption some suffer from, and that oil consumption would make more soot, but mine doesn’t seem to drink oil so the soot is just from diesel.

The real fix is the adblue system that reduces NOx emissions without using so much EGR flow, but we know that’s not getting retrofitted.

Tbh I’m not too bitter (yet…), I didn’t buy the car from Volvo, and the tax is £30 vs £300ish for the later adblue V60 D4 my dad has so if I have to clean the intake/EGR every few years I can handle that. I’m more frustrated I can’t be sure what the issue is yet - these symptoms seem to have been caused by(based on threads on this forum):
Split intake hoses
Blocked EGR cooler
Faulty EGR valve
EMAP sensor/blocked EMAP tube
MAP sensor dirty/faulty
Dirty intake manifold (and/or swirl flaps)
Dirty intake valves

The core issue is obvs soot going into the intake (possibly made worse by sticky oil soot from piston rings as you mention), but it’s so hard to differentiate between the causes until there’s an issue bad enough to cause a DTC.