D4 VEA 'check engine' light / EGR fault thread

[Stroudy]

V60 D4 Manual. 2014, 96k miles. EMU came on last week after a year of jerky pull aways when cold and surging also when cold. Went to my Pershore Volvo specialist for its full service and a known cambelt change. Has ended up being a new inlet manifold, EGR and cooler too, which was so sooted up the job has taken 3 days and a grand total (inc service and cambelt) of around £2300. Car does 90% motorway miles and around 500 miles per week. Is this something Volvo should be responsible for? They say the inlet manifold recall has already been done on the car, but are unable to see when as it wasn't at their Swindon dealership. It wasn't done in my ownership. Thanks all.

[Sotosound]

It should but, since the car is around 10 years old, they'll no doubt duck.

[aidanthomson]

Looks like I have the code for EGR again. Had it replaced during lockdown with full goodwill. Car is a 2015 D4 with 141,000 on the clock. Not sure what to do as was going to change soon. I also have been getting soot filter full message as well.

[xanxaz]

Hi, V40 D4 2015 115k km here, anyone knows if the Vacuum controled valve that actuates the flap on the EGR COOLER can be moved manualy? The Electrical valve is giving 20%-50% error most of the time. With car off, the valve sticks open if i push it by hand. But it still closes and have a EGR flow between 0 and 19g/s readings during driving. If the cooler is clogged completly would it still give any flow?
Symptoms are, rpm flutctuation at idle when cold, light aceleration is slow/labored and it will give a big hicup sometimes around 1200rpm in drive, Shifting gears the car is not smooth(manual), tendency to stall in low rpm where it should have more power, even compared to a gasoline engine. Tested the re-adaptation removing the battery, truth is the car drives perfect that first drive. EGR is off on first BOOT, afterwards starts, EGR valve opens as soon as i start the car and does like a Self test that opens and closes the valve 5 or 6 times or something and is there that RPM fail 825rpm to 730rpm drop for a split second and EGR Error above 60%. car has the newest pipe work done. Intake manifold is new, had Swirl motor stuck also...

[Miyo360]

So, I've got the warning light and the familiar error code P04D9, again. Its been two years exactly.

My story. Bought a '64 plate XC60, MY15 car in 2018, just 3.5 years old. Was high mileage at 113,000 (impressive for a 3 year old car). Within a year the P04D9 code showed up, Volvo agreed to replace for free. Fast Forward another 18 months and the same fault. Volvo again agreed to replace for free - this was supposed to be the final fix. Then in 2022 I get the code again. Was told Volvo will cover 50%, so instead, after reading up about cleaning the valve and cooler, I agreed that they would remove both, I would take home, clean up, and return the next morning for them to fit. This worked brilliantly. Based on experience, I expected this fix to last 18 months. Well, exactly 24 months later, the fault returns. I will ask for some Volvo good will, but I'm not hopeful. Car is 9.5 years old now, with just over 150,000 miles.

If they only offer 50%, or less, I will ask them to remove the parts for cleaning. I don't see the point in replacing with new parts, which cost €594 and €689 respectively if you can sufficiently clean existing parts. They don't appear to wear out, just get dirty.

On that note, does anyone have experience with an ultrasonic cleaners? Plenty of YT videos showing great results compared to chemical cleaning. And for around £150 for a suitable-sized cleaner, it seems a good option.

After the 4th occurrence of this fault I'm getting weary of this car. I'd prefer to part-ex it but I honestly cannot find another suitable car to replace it with at the same price-to-spec [sigh]. Anyone else resigned to living with it? Or are you all moving on to something else?

Also, anyone else had 4 replacements?!?

PS: Here are some pics of my cleaning effort in 2022.

[RDesign4Life]

Originally Posted by Miyo360

So, I've got the warning light and the familiar error code P04D9, again. Its been two years exactly.

My story. Bought a '64 plate XC60, MY15 car in 2018, just 3.5 years old. Was high mileage at 113,000 (impressive for a 3 year old car). Within a year the P04D9 code showed up, Volvo agreed to replace for free. Fast Forward another 18 months and the same fault. Volvo again agreed to replace for free - this was supposed to be the final fix. Then in 2022 I get the code again. Was told Volvo will cover 50%, so instead, after reading up about cleaning the valve and cooler, I agreed that they would remove both, I would take home, clean up, and return the next morning for them to fit. This worked brilliantly. Based on experience, I expected this fix to last 18 months. Well, exactly 24 months later, the fault returns. I will ask for some Volvo good will, but I'm not hopeful. Car is 9.5 years old now, with just over 150,000 miles.

If they only offer 50%, or less, I will ask them to remove the parts for cleaning. I don't see the point in replacing with new parts, which cost €594 and €689 respectively if you can sufficiently clean existing parts. They don't appear to wear out, just get dirty.

On that note, does anyone have experience with an ultrasonic cleaners? Plenty of YT videos showing great results compared to chemical cleaning. And for around £150 for a suitable-sized cleaner, it seems a good option.

After the 4th occurrence of this fault I'm getting weary of this car. I'd prefer to part-ex it but I honestly cannot find another suitable car to replace it with at the same price-to-spec [sigh]. Anyone else resigned to living with it? Or are you all moving on to something else?

Also, anyone else had 4 replacements?!?

PS: Here are some pics of my cleaning effort in 2022.

It will keep happening. The design is fundamentally flawed. The 180 degree bend in the cooler will never work without blocking. If you intend to keep the car the only permanent fix is an EGR delete and remap.

[Miyo360]

Originally Posted by RDesign4Life

It will keep happening. The design is fundamentally flawed. The 180 degree bend in the cooler will never work without blocking. If you intend to keep the car the only permanent fix is an EGR delete and remap.

Thanks. What are the legalities of deleting the EGR? And has anyone on this forum done it?

Re the 180 degree bend, I always thought this was odd as other coolers I have seen tend to be straight. I guess there isn’t a straight cooler that fits the existing valve right? Someone with some CAD experience could design a straight one to fit the valve and 3D print it in metal? Seems ambitious, but doable?

[Kev0607]

Originally Posted by Miyo360

Thanks. What are the legalities of deleting the EGR? And has anyone on this forum done it?

Re the 180 degree bend, I always thought this was odd as other coolers I have seen tend to be straight. I guess there isn’t a straight cooler that fits the existing valve right? Someone with some CAD experience could design a straight one to fit the valve and 3D print it in metal? Seems ambitious, but doable?

The car is 9 and a half years old, which is well past its warranty period. I'm afraid to say I don't think Volvo will contribute anything, certainly not the 4th time.

The legalities are, its illegal.