How to remove EGR / EGR Cooler Volvo V70 S60 XC90 2.4 D5 163 BHP MK2 DIY

How to remove Volvo 2.4 D5 EGR and EGR Cooler from V70, S60 or XC90.

Start by disconnecting the battery in the boot, remove the storage tray and disconnect the negative with a 10mm socket.

Remove the engine cover by tugging it straight up.

Remove the airbox, start by loosening the jubilee clip next to the MAF sensor. Disconnect the MAF sensor plug. Take the boost pressure sensor off it's mounting place. Remove the air intake plastic and then tug the whole airbox up hard.

Remove the anti rollbar with an 18mm and 15mm spanner for the top engine mount then remove the 18mm bolts from either side.

Remove the cold air intake all the way from the turbo to the front of the car. Loosen the Jubilee clip on the turbo. Remove a bolt from the middle of the alloy pipe and pull away from the turbo.

Undo the Jubilee clips from the EGR mixer pipe and the intake manifold hose, remove the pipe. Then remove 4 10mm bolts on the EGR Mixer and loosen another jubilee clip then you will be able to remove the EGR mixer.

Clamp off the the EGR cooler coolant feed to avoid loosing fluid It's upto you whether you clamp the coolant return as it doesn't lose a lot of fluid there.

Remove the coolant feed.

Remove the exhaust manifold heatshield by removing 5 10mm bolts.

loosen the EGR Feed from the exhaust side by either by loosening the clamp or removing 2 bolts from the other side.

Remove 2 14mm bolts that are clamping the EGR to the back of the engine.

The final bolt to remove is 12mm Remove the EGR actuator plug.

Now you should be able to wriggle the EGR and EGR cooler free.


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