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95 volvo 960-- removing/cleaning egr valve

Help, Advice, Owners' Discussion and DIY Tutorials on all Volvo's "mid era" rear wheel drive Volvos.
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95 volvo 960-- removing/cleaning egr valve

Postby jiggaz » 24 Dec 2009, 21:37

code 2-4-1, egr malfunction, any diagrams that can help me remove and clean the egr valve
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Re: 95 volvo 960-- removing/cleaning egr valve

Postby billofdurham » 24 Dec 2009, 22:45

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

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

Postby jiggaz » 24 Dec 2009, 22:51

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

Postby jiggaz » 27 Dec 2009, 01:21

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

Postby jiggaz » 31 Dec 2009, 16:16

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

Postby billofdurham » 31 Dec 2009, 18:40

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

Postby fpulipati » 28 Feb 2011, 12:58

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

Postby billofdurham » 28 Feb 2011, 18:48

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

Bill.
Please log in or register to see attachments.
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.
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billofdurham
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Re: 95 volvo 960-- removing/cleaning egr valve

Postby fpulipati » 01 Mar 2011, 15:51

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

Postby jimmy57 » 01 Mar 2011, 17:30

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

Postby billofdurham » 01 Mar 2011, 18:31

EGR is still listed for the '97 model with Motronic 4.4.

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.
User avatar
billofdurham
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Location: Durham, England
Model and Year: 855, 1995

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

Postby fpulipati » 01 Mar 2011, 21:23

Jim/Bill,

I cant seen any EGR tubes entering the intake manifold. I will look closer near starter. I dont find the rear EGR pipes routing to the other side of the block.
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Re: 95 volvo 960-- removing/cleaning egr valve

Postby fpulipati » 01 Mar 2011, 21:36

https://www.customers.volvocars.com/own ... n1997.html

using that and my vin YV1KS9609V111217, it seems like its w/o EGR, w/air pump. then what should P0401 mean? how to fix that?
fpulipati
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Re: 95 volvo 960-- removing/cleaning egr valve

Postby jimmy57 » 02 Mar 2011, 03:43

I looked over new car training book I had on 96 and it listed EGR delete as one of the benefits of upgrading to Mot 4.4 engine management.
If you can't see a rusty tube pass behind block/head meeting line and turn and go under back of intake manifold then it does not have it. THe plumbing is not that well hidden.
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