Was it replaced by the modified version of the EGR valve? Looks like it's a known issue for D4 engines: D4 VEA 'check engine' light / EGR fault thread - Volvo Owners Club Forum

 

Hi All. I am sharing my experience with this "well known" common EGR problem My car is a d4 (190) 2015 February manufactured. 133.000 miles in the clock now. Circa 30.000 miles ago, engine management light came up, and took my car to my long time used mechanic. No reduced power, no smoke, no stalling engine, my car was the same powerful as before the EM light. So my mechanic checked the fault codes, and we researched what was the problem and what would be the solution. As the EGR valve and cooler cost a fortune, we tried to clean both. So removed the EGR valve and cooler, and were not dramatically dirty, were not blocked. As we dismounted these we gave a clean and remove the black stuff from the cooler and valve (as it was advised in many relevant video). So we put back these parts, cleared fault code, and gave a go. Couple months later the EM light came back with P04D9 code. My car was still not show any recognisable issues, lack of power, or increased fuel consumption, or reduced engine power, nothing... Just the EM light. I advised to my mechanic lets dig into this issue as the EGR flow should be ok after the proper cleaning. Since that my car passed mot. I found EGR recall for v40s, unfortunately my car was not included in the recall, volvo confirmed 3times. Also i took my car to a private Volvo specialist who advised (after OBD check) change the EGR valve, and problem solved. I said, ok if a Volvo specialist advised this, lets do it. EGR valve was purchased by Volvo, and it was replaced, car passed the mot again. And? 2 days later EM light came back with P04D9 code. I was not a really happy bunny. Mechanic advised lets do a boost pressure test, it may help to identify the problem. I said in myself, you know what, you did a £700 job and did not solve the problem, I don't have much trust in you... So I bought an OBD reader, and decided to start a fault finding process, as my time is free, and still no symptoms with my car. The OBD reader has a function to check EGR valve position, EGR error, also testing the EGR Bank monitor. The EGR bank Monitor test failed, one of the component did not match with the minimum required voltage, but the OBD reader did not identified the component. I was suspicious from the beginning that it sounded me more likely an electrical issue more than mechanical (deposits, blockage). So I removed egr bypass pipe back to air intake side, cleaned it, it was not very dirty. Cleaned fresh air intake pipe after air filter. Checked any damage, leak or sealant issue what can be visible. I changed the EGR exhaust control (Pierburg 7.00515.05.0). Fault still there I changed Boost pressure sensor ( it was really dirty, original Volvo 31405341, new Bosch 261 230 423) Fault still there. So I would like to ask your advise. What else could trigger the P04D9 fault code? I would like to avoid another expensive replacement if it does not solve the problem. Thanks very much all comments, advises. Really appreciate your help Thanks Regards Gabi

Hi I have the same issue. Latest update from local garage is that it is not the EGR, it is actually a mass flow sensor, that gives wrong info to the EGR. This one opening and closing by the wrong info given and computer see as a foult of EGR not a flow sensor. £180 to replace (haven't done it yet, so will keep you posted. Kris

 

Hi
I have the same issue too. Do you have any news about? I have clean EGR twice and still the same . Thanks

 

Hi Gabi
Any news? Did you have your issue sorted?

 

Same issue for myself, had a been told it was fuel rail so changed that fault still there, low pressure fuel pump was the next suggestion again changed then was informed it's the injectors all by a Volvo specialist, cleared up for a couple of months now back to square 1, I so tempted to just pay for a EGR Valve delete as I'm not really happy to continue throwing cash at a fault noone can repair

 

I am struggling with a similar problem. No loss in power and car running perfectly. I’ve had a full regen done twice and it seems to intermittently clear the fault but keeps coming back. I’m loathed to throw money at this if it’s not going to fix the problem. The fault codes I got on last report were as follows


-Closed loop EGR Control at limit - Flow to low
-Engine oil level too high - General failure information no sub type Information

• Manifold air temperature circuit low. General signal failure. Signal stuck in range
• Camshaft position sensor A circuit intermittent (bank 1 or single sensor)

I’m not sure if the above is all linked.

Has anyone experienced similar issues? Would be interested to see if there’s a fix out there.

 

I had the exact same problem with my 2015 D2 R-Design.

The dealer I bought it from tried cleaning out the EGR valve a couple of times but the error kept coming back until they replaced the EGR cooler. Since then, I've had no issues at all.