How to remove the EGR, EGR Cooler and Throttle body on the Volvo XC90 2.4 D5 Euro 4 engine.

Intake Mainfold: [ Ссылка ]
Swirl Flaps: [ Ссылка ]

Remove the engine cover.

Remove the intake pipe for the airbox by removing the 2 8mm bolts at the front and squeezing the other end out of the airbox.

On the later XC90 the ECU is on top of the airbox. You'll need to disconnect the wiring for the ECU so make sure the key is out of the ignition (and keep it out) or to be extra sure disconnect the battery in the boot: [ Ссылка ]

Undo the jubilee clip for the MAF sensor and disconnect the wiring, to the right of the airbox there is a nut attaching the airbox to the body of the car (it's been missing on every car I've worked on). There's also a vacuum valve on the front of the airbox you can slide off the clip. You can now remove the airbox.

Release the wiring harness from the side of the engine near the high pressure fuel pump and disconnect all the wiring for components nearby.

Undo the jubilee clip for the throttle body and then remove the 4 8mm bolt holding the throttle body on (don't lose the gasket).

Undo the pipe between the EGR and the intake manifold, this will be filthy so will benefit from a clean also.

Remove the high pressure fuel pipe above the EGR with 2 15mm nuts and then you'll also need to remove the bracket on top of the EGR with 8mm bolts.

Follow the cold air pip to the turbo where the MAF was removed and you'll see a 10mm bolt half way down. Also remove the jubilee clip and remove the pipe.

On the side of the engine above the EGR cooler there is a 10mm bolt holding the Cooler to the block.

Now you'll have a really awkward jubilee to remove from the gold pipe which is the feed from the exhaust to the EGR, I managed with a really small socket and ratchet. Unfortunately the brake pipes leaving the ABS unit make it nearly impossible to use a screwdriver. Even when loosened the clip may not allow the pipe to be removed so you may need to twist a screwdriver in the gap to loosen it fully.

Remove the clips on the coolant lines on the EGR cooler. You won't need to clamp them as you'll only lose the coolant that's physically inside the cooler.

Finally remove the 2 15mm bolts on the front of the EGR and you'll be able to manipulate the EGR and Cooler out of position.

To clean the EGR there are lots of methods on YouTube, I tend to use a combination of Bojo scrapers, oven cleaner and even a steam cleaner when I have one handy.

Thank you for watching this video, I really hope it helps with your job.

These videos do take a lot of time to put together and often cost money in parts so I really appreciate the support I get when you like, subscribe and comment!

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