95 volvo 960-- removing/cleaning egr valve

jiggaz · Post by **jiggaz** » 24 Dec 2009, 14:37

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

Post by **billofdurham** » 24 Dec 2009, 15:45

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: (576.03 KiB) Downloaded 2023 times

Bill.

jiggaz · Post by **jiggaz** » 24 Dec 2009, 15:51

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

jiggaz · Post by **jiggaz** » 26 Dec 2009, 18:21

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!

jiggaz · Post by **jiggaz** » 31 Dec 2009, 09:16

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.

Post by **billofdurham** » 31 Dec 2009, 11:40

Thank you for the update.

Bill.

fpulipati · Post by **fpulipati** » 28 Feb 2011, 05:58

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.

Post by **billofdurham** » 28 Feb 2011, 11:48

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: (96.42 KiB) Downloaded 1796 times

Bill.

fpulipati · Post by **fpulipati** » 01 Mar 2011, 08:51

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.

Post by **jimmy57** » 01 Mar 2011, 10:30

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.