95 volvo 960-- removing/cleaning egr valve

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jiggaz
Posts: 8
Joined: Thu Dec 24, 2009 9:26 pm
Year and Model: 95 volvo 960
Location: us

95 volvo 960-- removing/cleaning egr valve

Postby jiggaz » Thu Dec 24, 2009 9:37 pm

code 2-4-1, egr malfunction, any diagrams that can help me remove and clean the egr valve

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billofdurham
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Posts: 6508
Joined: Thu Feb 02, 2006 10:31 pm
Year and Model: 855, 1995
Location: Durham, England

Re: 95 volvo 960-- removing/cleaning egr valve

Postby billofdurham » Thu Dec 24, 2009 10:45 pm

Welcome to Matthew's Volvo Site.

Have you erased the code? I am a firm believer in erasing codes and running the car to see if they return. Quite often the code is set by a one off occurence and nothing is actually wrong.

The EGR valve on the 960 is electronic and there are differing views on whether or not it can be cleaned.

I don't have a diagram for cleaning but to replace the EGR valve you need to remove the starter motor and oil dipstick pipe. Slacken the pipe connections to the EGR valve, slacken the EGR valve screws and remove the valve and seal.

Have you tested the EGR valve using the On-Board Diagnostic unit?

960 EGR valve test.pdf
(576.03 KiB) Downloaded 1268 times

Bill.
Work was good - retirement is better.

1996 850GLT 2.5 20v Estate Manual.
1995 Peugeot Boxer 2.5Tdi Autosleeper.
Previously:
1984 244DL, Manual, Beige.
1987 744GLE, Manual, Green.
1991 960 3.0 24v, Auto, Silver.
1994 940T Wentworth, Auto, Blue.

jiggaz
Posts: 8
Joined: Thu Dec 24, 2009 9:26 pm
Year and Model: 95 volvo 960
Location: us

Re: 95 volvo 960-- removing/cleaning egr valve

Postby jiggaz » Thu Dec 24, 2009 10:51 pm

I have cleared the code and it came back, also failed emissions with high HC and NOx. have not yet tested, I will do that tomorrow

jiggaz
Posts: 8
Joined: Thu Dec 24, 2009 9:26 pm
Year and Model: 95 volvo 960
Location: us

Re: 95 volvo 960-- removing/cleaning egr valve

Postby jiggaz » Sun Dec 27, 2009 1:21 am

I did the tests #1 did not activate the EGR like it says and I could not find the wires described on 2,3 & 4.
I also tried to remove the EGR valve but cannot reach the valve screws without removing the intake pipes so I have resorted to have a mechanic replace the EGR valve. Thanks for all the help!

jiggaz
Posts: 8
Joined: Thu Dec 24, 2009 9:26 pm
Year and Model: 95 volvo 960
Location: us

Re: 95 volvo 960-- removing/cleaning egr valve

Postby jiggaz » Thu Dec 31, 2009 4:16 pm

Update on cleaning the EGR valvle.
On my vehicle, I had to remove the spark plug rail, detach the air flow pipe from the air filter in order to remove the intake pipes(replaced the clips as well) and manifold. this gave me all the room needed to remove the EGR valve and pipes with ease. Cleaned out the gunk in all the pipes that I removed and then tested the valve to make sure it closed.
Took about 3hrs but after that, passed emissions(reduced NOx from 1670 to 276) and no gas fumes from exhaust.

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billofdurham
MVS Moderator
Posts: 6508
Joined: Thu Feb 02, 2006 10:31 pm
Year and Model: 855, 1995
Location: Durham, England

Re: 95 volvo 960-- removing/cleaning egr valve

Postby billofdurham » Thu Dec 31, 2009 6:40 pm

Thank you for the update.

Bill.
Work was good - retirement is better.

1996 850GLT 2.5 20v Estate Manual.
1995 Peugeot Boxer 2.5Tdi Autosleeper.
Previously:
1984 244DL, Manual, Beige.
1987 744GLE, Manual, Green.
1991 960 3.0 24v, Auto, Silver.
1994 940T Wentworth, Auto, Blue.

fpulipati
Posts: 8
Joined: Thu Feb 03, 2011 3:58 pm
Year and Model: 960 1997
Location: US

Re: 95 volvo 960-- removing/cleaning egr valve

Postby fpulipati » Mon Feb 28, 2011 12:58 pm

Can someone help me? I have a 1997 960, it has check engine light on with P0401 --insufficient EGR flow. I am trying to locate the EGR valve based on this thread here and this link for location, but i dont find the EGR feeling my way with hand or visually.
http://www.volvopartswebstore.com/image ... -68485.jpg
The intake does not have the attachment hole or the tube going to the header side.

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billofdurham
MVS Moderator
Posts: 6508
Joined: Thu Feb 02, 2006 10:31 pm
Year and Model: 855, 1995
Location: Durham, England

Re: 95 volvo 960-- removing/cleaning egr valve

Postby billofdurham » Mon Feb 28, 2011 6:48 pm

Welcome to Matthew's Volvo Site.

Possibly a diagram with parts description may help. Also in the attached is the VADIS method for replacing the EGR valve.

960 EGR valve.pdf
(96.42 KiB) Downloaded 665 times

Bill.
Work was good - retirement is better.

1996 850GLT 2.5 20v Estate Manual.
1995 Peugeot Boxer 2.5Tdi Autosleeper.
Previously:
1984 244DL, Manual, Beige.
1987 744GLE, Manual, Green.
1991 960 3.0 24v, Auto, Silver.
1994 940T Wentworth, Auto, Blue.

fpulipati
Posts: 8
Joined: Thu Feb 03, 2011 3:58 pm
Year and Model: 960 1997
Location: US

Re: 95 volvo 960-- removing/cleaning egr valve

Postby fpulipati » Tue Mar 01, 2011 3:51 pm

Thank you Bill!

I will take a look at this, I get a better picture in my mind, seems like EGR is below the starter.

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jimmy57
Posts: 5204
Joined: Fri Nov 12, 2010 4:25 pm
Year and Model: 2004 V70R GT, et al
Location: Ponder Texas

Re: 95 volvo 960-- removing/cleaning egr valve

Postby jimmy57 » Tue Mar 01, 2011 5:30 pm

It is above the starter. I thought the 960/s90/v90 96-98 did not have EGR after the change to Motronic 4.4 engine management.
Possibly California emissions had them.


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