Volvo VEA Diesel EGR + Manifold Removal/Cleaning (V40 and other models) 

How did you get on ?

I've missed capturing that in the video, but it is a good point 👍

Hi, It really depends on the current state of the manifold. Sometimes carbon gets between the manifold and the runners shaft which can't really be cleaned manually. There are more professional methods with chemicals and ultrasound cleaning, but I'm not 100% if they would equally be applicable for plastic components. Unfortunately volvo had designed the manifold without the possibility of physically removing/deleting the runners, so best option would be to try giving it a good clean. The runners actuator is an easy one, you can remove it on its own and if you switch to ignition 2, I think from memory it would move once to closed/open position. Good luck.

Thank you - I'll let you know how it goes in a few weeks when I'm done@@GSAuto681

@@GSAuto681 I cleaned my inlet manifold & ports using this video as a guide. I removed the manifold with the high pressure pipe left in place by removing the engine cover support on the top of the manifold at the LH end. It was in a right mess & I think this was the dirtiest job I've ever done but well worth it. I had intended cleaning the EGR valve/cooler as well but on the day did not have apprpriate tools to remove the 2 bolts holding the pipe at the rear of the EGR valve. In my case they are Torx screws rather than hex bolts. This will have to wait for another time. The EGR valve action was also very stiff (I wouldn't have been aware if I wasn't doing the maintenance) but I managed to make it operate very smoothly using WD40 and a little high temp grease. The actual swirl flap assembly can be carefully unclipped from the manifold moulding which gives better access to clean both parts. Reassembly with new gaskets went well & I've since done about 2000 miles with a much smoother engine. I've since bought a small OBDII scanner and I can see in live data that the flaps are correctly following the demand accross the whole range 0-90 deg. I do still however have a remaining problem. DTC P200900 sometimes gets reported on its own but not consistently - I may go several hundred miles or just a few. The freeze frame data doesn't seem helpful as it shows the engine not running. Any clues or advice?

@@user-yp5fb5kg3y Hi, I'm glad you've found the video useful. In terms of the fault code, that seems to me like a few things. It's either the runners still slightly sticking (quite disappointing volvo didn't make them deletable), it's the runners actuator not been mounted back correctly (if you've disassembled it), or it's the wiring/actuator itself. If you are going to verify the actuator mounting, before putting it back on the manifold, you can quickly verify its operation by switching to ignition 2, which will make it test itself/make a full arm movement, so at least you can rule out the actuator mechanism. Good luck with that!

Absolutely. In fact on those engines most of the time it's the EGR cooler and not the valve, but surely if you taking it off can give a good clean to both!

No Is the answer. :-(

Try using a spanner or a long ratchet.

Thanks@@georgistefanov9166 . I have removed the part from back of the engine of the intake and with a long ratchet you have some space .

I'm having the same problem getting rid of the screws on my car, the screws are T30 torks, and it's impossible to remove. It's stuck. I've already applied WD to try to alleviate it, but I can't remove them.

Hi, it's been done on my car already, but if I can find a donor might give it a try.

It's not a hard job although Volvo will tell you it is and you need a timing tool to remove the lower crankshaft bolt, you don't I used white marker on crankshaft bolt and cam bolt the injector pump locks up with a 8mm bolt

@@GSAuto681 Let me ask you one more question about changing the timing belt. The camshaft moves slightly when tightening the timing belt tensioner. How do I adjust the timing belt tension?

@@stephenlockwood437 What is the white marker going to do on the crank bolt?

​@@fredflintstone2077 you can buy the Volvo tool to hold the crank shaft in place there are timing marks against the lower pulley and crankshaft oil seal the white marker will highlight these marks most automotive guys put the white marker on there so they are 100% sure the engine is still in time

It seems the 2.0 VEA D5 is the same but has more power due to different ECU mapping. The "D5" is very different.

Vea d5 is i think the same, it just has a different tune on it