I picked the car thinking this is it until the next service but the car just feels very different. Turbo is not kicking in at all in low revs, engine sounds like it is strugling when accelerating and has developed new sounds, something i didnt hear before. It is just not the same car as beforr it had the repair done. Anyone else with EGR fault had this issue after the repair and was it resolved?
Is yours definitely the 4-cylinder D4? It's possible you may have the 5-cylinder 2 litre diesel which was also badged as a D4.
In any case, the car should drive exactly the same after an EGR fix, but it doesn't sound like yours has had the EGR done if you were told it's an 'intake manifold fault'. Take it back to the garage and get them to look at it.
My guess is that they've not properly reconnected a vacuum pipe to a VNT actuator, or got them mixed up.
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Thanks Craig,
I am certain this is a 4 cylinder engine. Got it booked in for this wednesday, ill report back the findings here then. This is the 4th time in 9 months i am visiting the garage due to volvo design flaws.
I am also thinking they might have done the software update and remapped the engine to drop the performance and eliminate future clogg ups. It really feels like it is a totaly different car, it took me whole 2 minutes of driving to notice.
Thanks,
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I am certain this is a 4 cylinder engine. Got it booked in for this wednesday, ill report back the findings here then. This is the 4th time in 9 months i am visiting the garage due to volvo design flaws.
I am also thinking they might have done the software update and remapped the engine to drop the performance and eliminate future clogg ups. It really feels like it is a totaly different car, it took me whole 2 minutes of driving to notice.
I had three fixes done on my 2014 V60 D4, none of them made any difference at all to performance or driveability, it was always good and strong. I'm betting the garage has not reassembled things correctly.
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I'm looking to buy a 2014/15 V60 D4 within the next couple of months and this ERG issue is putting me off. I won't have the luxury of finding an affordable one from a local Volvo dealer so I'm wondering how I can be sure that when I view one with, say, 100k miles on it, that I can know that the components have been upgraded. FSH these days just seems to consist of a load of stamps in the service schedule book; its becoming rare to get a full stack of bills. I expect I'll get a blank look if I ask an independent dealer if it's all sorted. And I'm guessing there's not the equivalent of a recall website where you can see if a vehicle has had official patches applied. Makes buying a D4 VEA vehicle a bit of a gamble :(
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Hi
Here are my problems with my14 V60 2014/02 D4 181HP:
I have had several EGR pipes, cooler, valves exchanges (in 2016, 2017, the last one november 2018... the volvo dealer is persuaded that the prblem will come back!).
My car has now 128000kms.
Since the car passed 80000kms, the engine burns more and more engine oil, about 1 liter every 1300kms. No external leak.It is over Volvo standard (0.5liter/1000kms).
An official car expert has detected cylinders leakages (from 20% to 60%).
The only solution, change the engine, it will cost me a lot. Volvo doesn't want to participate. Or to add oil every 1300 kilometers....
So to be honest, look for an other brand!
Chris
my14 V60 D4 181HP Summum D4204T5 VEA Engine
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Hi I am on my second XC60 full Volvo service history and low and behold at 65000 miles I got the engine warning light and a tortoise on the dash.!. I contacted my Volvo garage and they said "no problem we know what it is you need a new EGR,ITS COVERED BY THE WARRENTY just keep driving and we will order one in , I thought this only happened with low mileage cars? a bit worried but happy days. In it went got the swap back on the road a few weeks later the same lights, O SAID VOLVO bring it in, This time sad face "you need a new EMAP pipe this one has furred up unfortunately it is not covered by the warranty so that will be £170," "O said I seems a bit funny that ,may be its got something to do with the previous fault ", Don't think so sir but we will ask Volvo UK. Volvo UK say as a good will gesture we will do it for free, Back on the road again happy face.
Few weeks later its first MOT time sales through but now its out of warranty!!!!!!!
Month later the lights are back on
This is were it gets sad, in to garage, new engine 2 of the bores are cracked.!!
I have been told that initially Volvo will put 40% to the cost as another good will gesture.
Any body got any ideas if the previous faults could have contributed to the catastrophic failure of my otherwise bullet proof Volvo, I was looking forward to a new XC60 IN THE SUMMER.???????? (they don't build them like they used too )
Sad face.
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Any body got any ideas if the previous faults could have contributed to the catastrophic failure of my otherwise bullet proof Volvo, I was looking forward to a new XC60 IN THE SUMMER.
Sorry to hear about your troubles. Unfortunately I don't think the EGR-related problems will have caused the cracked cylinder bores. I no longer have a Volvo but I still visit the Volvo forum semi-regularly and while there are one or two cases of high oil consumption and related low cylinder compression (which may be related to a cracked bore), it's not yet a common problem, compared to the number of VEA motors in use.
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Any body got any ideas if the previous faults could have contributed to the catastrophic failure of my otherwise bullet proof Volvo, I was looking forward to a new XC60 IN THE SUMMER.
Sorry to hear about your troubles. Unfortunately I don't think the EGR-related problems will have caused the cracked cylinder bores. I no longer have a Volvo but I still visit the Volvo forum semi-regularly and while there are one or two cases of high oil consumption and related low cylinder compression (which may be related to a cracked bore), it's not yet a common problem, compared to the number of VEA motors in use.
For me, EGR problem and Oil consumption are linked.
EGR not fixed make lot of soots.
Soots come into the cylinder , soot + oil clog the piston rings.
Then piston rings become inefficients.
And then the motor burn oil.. and make more soots ...
Did the EGR clog the pistons or did the pistons fail and clog the EGR?
Edited by ChrisFromFrance on 20/02/2019 at 13:19
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This is just a scandal. The EGR in this engine is rubbish and owners are being told to suck it up and cough up the cash. Warranty has not solved the problem and now some dealers are quietly passing on the problem to the next owner. VW and Volvo have a real problem with this equipment because it tried and failed to provide an emissions/ fuel efficiency solution. VW lied and came a cropper and Volvo appears to be going down the same route. If no one else has splashed this to the national media motoring correspondents then perhaps now is the time. I will contact a few and let you know if this will fly as a story. If people on this string are willing to talk to them and give them their stories then let me know and I will put you in touch. I have just been asked to cough £636 for a new EGR after spending £120 on a new air mass sensor. Had enough - time for Volvo to hold their hands up and save their reputation. (There is interest already - see city am here www.cityam.com/271109/volvo-facing-600m-hit-over-c...d
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Absolutely gutted I have been totally satisfied with my 2014 2 litre diesel FWD XC60 bought from a reputable main Volvo dealership in Eastbourne East Sussex some two years ago, the car has lived up to my expectations until today. So car picked up for a service having previously rung the dealer service department as a amber warning light comes up which say simply, in the owner car manual it’s an emissions issue and told that’s fine unless it’s a red engine sign, so happily I carry on driving with no loss of power for the next week until service day arrives and a midday phone to say my EGR valve and cooler needs replacing at a discounted price of just over £1100 but thank god I found this site and forum, why on Earth are Volvo selling the D4 engine in various guises throughout the model range knowing quite well there is an inherent problem, the car is simply not fit for purpose and by now there should have been a recall, not just wait and see when it becomes a problem and lucky for some when it’s under the warranty. The car has been a real workhorse and a pleasure to drive it fits the bill and does what we need it do but for pity sake, Volvo need to get their head out of the sand, this is a time bomb situation and I feel deeply disappointed that with an iconic brand known for safety, dependability and reliability this is almost embarrassing failure to put right something that has been an engineering and design elephant in the room scenerio, you can not ignore this problem it’s a huge issue which will have a resonating effect and they know it, so it’s my mission now to take it up initially with the branch and then with Volvo direct, no way am I forking out over a grand only to pay for their mistakes, and if that does not work then it goes to the media and motoring journalists. Feel cheated and somewhat disappointed with not having previous knowledge of this consistent fault it certainly would have been one that I would have not chosen in a prestigious car which I believed had a pedigree of Volvos reputation.
Edited by SussexFactor on 01/03/2019 at 22:40
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Good stuff Sussex Factor. I have paid for a new egr and got that check engine light after 2 miles of driving followed by the tortoise and reduced engine performance after 5 miles. Very sick. I will also be talking to Volvo and talking to some neighbours who are at the top of the automotive industry globally. I think we should follow up in parallel with the media and will be contacting them tomorrow. My email is grahammrtaylor@btinternet.com if you want to plan together.
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Good luck both of you. As with any such endemic problem, having a full Volvo service history is a big help with this situation.
See also this 2000+ post thread about the issue on the Volvo forums for other owners' experiences: www.volvoforums.org.uk/showthread.php?t=221555
Bottom line is, if you've got a VEA diesel engine and it develops EGR problems, it should be a warranty / goodwill job. Every Volvo dealer knows about this issue, as every Volvo dealer will have handled dozens, if not hundreds of EGR valve / cooler replacements.
My own 2014 V60 D4 came from a large Volvo main dealer in Warrington, and I had 3 EGR coolers (all updated components supposed to give a definitive fix) and one new EGR valve during my ownership. I was told by the service team there that they were doing the fix on between 5 and 10 cars per WEEK from the start of 2015 onwards. A Volvo dealer who claims they don't know about the problem, or that it affects only a small percentage of VEA engines is, quite simply, lying through their teeth.
The EGR system as originally designed is fundamentally not up to the demands of real-world driving and meeting Euro VI standards, a fact which Volvo has now tacitly acknowledged by adopting AdBlue-based NOx reduction on the VEA engine (in line with most diesel engines from other manufacturers).
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Tbh prepared to kick up a stink when we went into the branch, but spoke to manager and he is getting the new erg and the now final fix modification done through a goodwill gesture by Volvo, waiting on confirmation when car is going to be booked in to service department, so great result ,but will keep you updated
Edited by SussexFactor on 08/03/2019 at 21:04
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Wow. Looks like a result. I have a Volvo trained mechanic going straight to Technical HQ at Volvo in the coming week. I will be using your experience to promote my case if that is ok with you. Let me know how you get on as soon as. Regards GT.
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Hi
I'm from France and I have big issue with a V60 D4 181 my2014 volvo.
I have several EGR pipes, cooler, valves exchanges (in 2016, 2017, 2018).My car has now 131000kms. Full history Volvo.
Since the car passed 80000kms, the engine burns more and more engine oil, about 1 liter every 1300kms. No external leak. It is over Volvo standard (0.5liter/1000kms).
My Expert (amicable procedure) detected cylinders leakage (from 20% to 60%) depending of the cylinder. There are also leaks by the intake valves. Volvo asks me to remove the breech.
Volvo wants me to pay for diagnose the engine (remove the breech) and it will cost about 2500€ to remove and replace the breech.
So it will cost me a lot.
If you could help me it would be great.
my VIN number; YV1FW73CDE1198717
Thank you.
Chris
my14 V60 D4 181HP Summum D4204T5 VEA Engine
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So the situation as it stands is two weeks ago we went into the branch and spoke to Joules the manager and explained the situation simply the XC 60 offered at an attractive price having looked at other SUVs from alternative manufacturers and dealers seemed the best option for my budget listed at 24K but given a promotional price of 23K, I used half of my Mother’s gift of inheritance and then to hell with it ! cashed in an ISA plan, so with our part exchanged Citroen C4 the deal was struck on a 9500 miles 2 year old perfect example and stunning Volvo. The manager was quite confident Volvo was likely to carry out the work replacing the EGR valve as a matter of goodwill, as quite rightly my opinion was you sold us a timebomb, knowing quite well the historic chance this component could fail, and following my subsequent research why on earth had this not been upgraded before we bought the Car in the first place, so bringing you upto date, we have been waiting for a response from Caffyns Eastbourne , but one week later I contacted the branch to see how things were progressing, this was handled by the general manager who’s comment was this, that it was the first he had known of the situation and he would discuss it in the branch managers meeting tomorrow and get back to us as soon as possible, but nothing has transpired, so as I write, I await Joules phone call to advise me what is exactly happening, was this a false promise of resolution and over stepped his position in command and his committed decision to put the situation in front of Volvos customer care and sort it out, I wait with for the phone to ring.
Edited by SussexFactor on 20/03/2019 at 10:48
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@SussexFactor - you'll wait forever for a car dealer to call you when you want to BUY a car, let alone try and get some warranty work done. In my experience, nothing happens unless you chase them.
Edited by craig-pd130 on 20/03/2019 at 12:16
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Hi Craig I have now had a response by the service manager who’s name is Mike, who says Volvo have agreed to a 70% discount on their prices, it still however leaves me with a bill of 62p short of £500 quid to pay for a inherent design fault, which I seem to be paying for their mistake and gamble as and when it would be a problem, it’s like there’s thousands of Volvo cars out there just fitted with either the D4/D5 series engines ( EGR valve/ cooler issue) and it’s simply a matter of time, a lottery as it could been seen, as to when eventually they will fail, so it could be a matter of a few months or a few years, my stance on this is that a product should be fit for purpose, and any failing part as a result of bad design or engineering no matter the window of time, unless tampered or unauthorised modification must and should always be the responsibility of the manufacturer and like the dealership, for they know the issue yet sell the product with the knowledge this exists, they will always be the first point of contact and as a trusted franchise need to honour and satisfy the customer regardless of who is negligent.
I am likely to copy this to Volvo customer services as unfortunate as it may be why should anyone have to endure financial loss as a result of corporate failure to address such as a major manufacturing fault from a leading European Car Brand, its outrageous and appalling forfeit of justice that the customer deserves better service and better loyalty.
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@SussexFactor - exactly how old is your car? And it was definitely bought from a Volvo main dealer, and has always been serviced by a Volvo main dealer?
If you cannot honestly answer 'yes' to the last two questions, then 70% is a decent offer and I would take it.
But if you can honestly answer yes to those questions, then I would go absolutely thermonuclear with Volvo UK (not the dealer, but with Volvo UK customer services) by email and phone: using choice phrases such as "I bought Volvo for its reputation for quality and safety, and you would agree that my experience has fallen a long way short of that. I am extremely disappointed in this experience with my Volvo, especially considering that this is a highly publicised and well known fault with the D4 engine, and I expect better from such a trusted manufacturer, especially when I bought it as an approved Volvo used car with full service history, etc etc ...."
Keep at it, I've managed to get all sorts of out-of-warranty work done free on various marques by being a 'not angry, just very disappointed' customer. Don't get stroppy or insulting, just stick to the facts and keep at it. Their default position is always 'no' - so keep pushing.
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Morning Craig
Your absolutely right in the approach I should take and I will speak to them again, especially after the first contact at the branch from the now known identified service manager, gave the impression it would at all costs would be dealt with under a goodwill gesture by Volvo and was quite confident, giving the impression this problem was quite seen as normal protocol. So we believe the best thing is again relaxed but assertive meeting face to face with a manager and go for a 100% for exactly the reasons you mentioned and yes it has always had a full service history and bought directly as you say with Volvo assurance policy, with only a 3 month delay in servicing due to personal reasons and a unplanned trip abroad over Christmas, so we average about 9500 miles a year so having a strict yearly service is not a priority when the actual mileage they say between services is some 17000 miles.
Just to add I will give Caffyns the chance to review the situation and respond then contact Volvo direct customer services should the response not be a favourable.
We will see what happens, so watch this space as they say
Cheers Steve
Edited by SussexFactor on 22/03/2019 at 09:07
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V60 VEA D4, 72k miles, FVSH and just over 4 years old. A few days ago I had an almost complete loss of power that rendered the car undriveable, warning message ('reduced engine power') plus a tortoise symbol... I read the error codes using an ELM327 that I carry around with me and found a P2413. Car was recovered to a nearby Volvo dealer who confirmed that the EGR valve was stuck open and in need of replacement... during this replacement the EGR cooler was found to be partially blocked and deemed to be also in need of replacement (and apparently this had already been replaced once before!). Volvo goodwill covered 100% of the cooler, but only 50% of the valve, so I got a bill for £373 (included £60 for diagnostics).
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"....we average about 9500 miles a year so having a strict yearly service is not a priority when the actual mileage they say between services is some 17000 miles."
Be careful - when I had a V60 the service intervals were one year or 18,000 miles, whichever came first. A good system, and one where you know where you are. Preferable I think to intervals generated by a car's computer.
Maybe yours was different, Sussex Factor: but on the face of it Jon above seems to have got a better deal. Volvo should of course be making sure that all cars with full Volvo service history are treated consistently.
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Hi thank you for your comment and just to update although the dealership told my wife and myself there was no history that any previous work or issue with the EGR valve had been recorded, Volvo Head Office have since advised the car produced in 2014 recieved a new Valve and presumably cooler during the the following years 2015 and successive 2016, so presently in the hands of Volvo customer services and they are in talks with the Eastbourne dealership today Friday 29th March.
Feel disappointed there is an element of mistrust now in who exactly is telling the truth, don’t need smoke and mirrors, need the fault resolved once and for all and no cost to the end user meaning me the customer. Update due next week staying cool, polite and optimistic !
Edited by SussexFactor on 29/03/2019 at 15:38
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Hi thank you for your comment and just to update although the dealership told my wife and myself there was no history that any previous work or issue with the EGR valve had been recorded, Volvo Head Office have since advised the car produced in 2014 recieved a new Valve and presumably cooler during the the following years 2015 and successive 2016, so presently in the hands of Volvo customer services and they are in talks with the Eastbourne dealership today Friday 29th March.
Do you have the car currently? There's an easy way to check if it's ever had the latest updated EGR modifications. See this post here on the Volvo forums:
www.volvoforums.org.uk/showpost.php?p=2426426&...9
Bottom right of that picture you can see a hose about the thickness of a garden hose which has 2 jubilee worm-drive clips on it. That shows the engine has had what was supposed to be the 'definitive' Volvo EGR cooler fix (they re-routed the EGR coolant flow to keep the EGR cooler hotter, in an attempt to stop condensation).
Lift your bonnet and have a look (no need to remove engine cover). If your car has those clips, then the dealer is either barefaced lying, or incompetent.
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It seems that there are 2 differents case on these VEA engines:
EGR valve should have been replaced once.
EGR Cooler:
1st case:
The engines with only the final EGR Cooler seem not suffering from oil consumption.
2nd case:
The engines with intermediate EGR cooler fix (2016) and then with the final EGR Cooler seem suffering from oil consumption.
Is this intermediate fix responsible of clogging intakes valves, piston rings ...
__________________
V60 my14 D4 181 HP VEA Summun Geartronic 8 speed
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Ok this is the latest and hopefully the final entry, my Volvo was taken into the dealership some 6 weeks ago now, they had the car for about 8 working days and having stripped it down to the essential components such as EGR, cooler pipe that seemed to have had the infamous final fix indicator of two jubilee clips in place, and exhaust manifold sooted up cleaned and returned, but as a result they found the some inlet and exhaust valves were sticking and the tolerances were wrong ? So this warranted an actual bill of some £4000 as I was led to believe by the service department, however when Volvo UK were contacted, by the grace of God and with the goodwill gesture of the warranty management or customer services of Volvo my contribution was only part that being still a hefty £575. I conceded and accepted the deal without hesitation when consulting Quentin Wilson a friend of my late mothers and on his advice I simply went forward with the fix, and reluctantly but with satisfaction accepting his word rather than anymore stress, I said well let’s just get this done and put it behind us.
The car does seem better albeit a little sluggish on the pull away pick up speed, but having had a latest software upgrade/ update installed on the last service may find the difference in noise attributed to that alteration.
Message to self from now on, use Redex treatment every 10 to 12 weeks with a full tank of fuel, to ensure the DPF EGR is cleaned as simply I am not sure if using Shell specifically designed with cleaning solvent additives is cost effective or adequate, so that’s what I will do in the future, Redex and long fast motorway runs to dissipate the clogging up which seems to be the inherent problem with many modern day diesels, even when using Adblue on some models it’s simply a pain ! Whatever
Thanks all for your help along the way, I hope my experience may help others, just don’t trust the word of some dealerships, and try and do your homework before buying what could be a liability on four wheels.
Cheers Steve
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Hi see my latest update and hopefully this has been resolved for once and all, will be using a Redex additive in the fuel periodically from now on tbh
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Graham Taylor no relation here again with some good news. I had my Volvo trained mechanic order an egr from a Volvo dealer. Engine check light and tortoise lights reignited after a couple of miles. So .... got my mechanic to ring the dealer and book the car (XC60 Dec 2014 D4) in. The car was fixed three days later. Volvo donated some £800 of parts for free and I just paid the labour. Amazing. Looks like a new engine. Many miles of pipes, rods, and notably a software update that only Volvo has. The problem I was told occurred only in the UK. CONDENSATION messes everything up. I am now a very happy bunny. EGRs can be fixed but I might go for hybrid or electric next time. The days of diesel are numbered.
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Graham Taylor no relation here again with some good news. I had my Volvo trained mechanic order an egr from a Volvo dealer. Engine check light and tortoise lights reignited after a couple of miles. So .... got my mechanic to ring the dealer and book the car (XC60 Dec 2014 D4) in. The car was fixed three days later. Volvo donated some £800 of parts for free and I just paid the labour. Amazing. Looks like a new engine. Many miles of pipes, rods, and notably a software update that only Volvo has. The problem I was told occurred only in the UK. CONDENSATION messes everything up. I am now a very happy bunny. EGRs can be fixed but I might go for hybrid or electric next time. The days of diesel are numbered.
It sounds like your mechanic bought and fitted a replacement EGR valve, only to discover that the problem was actually a blocked cooler? For info, Volvo usually make a full 100% parts and labour contribution towards the cooler and a 50% contribution towards the valve. As posted above a couple of months ago, this was my recent experience, resulting in me paying 'only' £337 towards a total bill of around £1600.
Condensation occurs on the inside of the cooler and then mixes with the accumulated soot, this mixture then sets hard as it dries and eventually causes a solid blockage... this was worse on the original version as it was actually over-cooled (the revised cooler can be identified by where it connects into the engine coolant system, hence the need to fit revised pipework. I really can't see how this could be a UK-only problem and suggest that someone has got confused about the formation of the condensation being a weather-related external issue?
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EGRs can be fixed but I might go for hybrid or electric next time.
However any recent car including hybrids that have and internal combustion engine will usually have some sort of EGR function - be it via a valve or variable timing
Edited by Big John on 30/05/2019 at 00:41
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Does it make a difference if I go for the D4 5-cylinder? Will I still have EGR problems?
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Does it make a difference if I go for the D4 5-cylinder? Will I still have EGR problems?
No, this specific EGR problem does not affect the earlier 5-cylinder engines. The 5-cylinder is a strong engine, but the youngest one will be 6 years old now, and they are not immune to wear & tear / neglect.
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I’m about to buy 2015 xc70 100k miles d4 and dealer says he will fit egr cooler. Engine light on. Told me Volvo came up with new egr to solve a problem they had. Was looking forward to buying now put off. Do you or anyone know if the problem has been resolved definitively I don’t want car continually garaged with big bills.
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dealer says he will fit egr cooler.
How do you know when a car salesman is lying? He's got his mouth open.
Hope you've not put a deposit down? My usual response to that sort of promise is to say call me when you've had it done and I'll come back. Never had the call!
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