I just got an 89 245. It was a CA car and has an EGR system on it.

The only experience I have with EGRs is on VW TDIs where they do a great job clogging the intake manifolds with carbon.
Are there unintended long term problems with the EGR systems on the redblocks?
Does it do anything to help fuel economy?

Thanks!

Andrew

EGR reduces fuel economy by about 1 mile per gallon, or so I have read, versus the same auto using the same engine management without EGR.

You are in San Antonio, TX?

Long term EGR issues with your 1989 240? Yes.

Two stainless EGR pipes.

First between the manifold to the EGR valve intake. This stainless steel pipe begins to rust from the exhaust manifold onward. Eventually corrosion is so great the pipe breaks and may prevent the engine being able to hold idle as well as a rather large exhaust leak from the manifold through the pipe to the break. Also, the stack of hardware thet secure that end of the EGR pipe to the exhaust manifold becomes loose. Maybe the knurl of the pipe compresses over time. So, you may have a small leak there. A plug exist sold by Volvo, though you need a crush washer and I'm not sure a copper washer is best.

The second pipe is at the EGR valve outlet to the air intake manifold. The exhaust gasses condensate at the end along the inside of the pipe starting at or near the union with the intake manifold moving backwards. The result is a fault with what the EGR temperature sensor encounters. EGR is on, as controlled by the Bosch EZK ignition module controller or computer, yet the EGR temp sensor does not encounter the warmer exhaust gasses passing through the EGR piping. Your Bosch EZK116 will report a fault and I guess a check engine light illumates on the dash.

You do know how to access and use the OBD-1 on your 1989? See here:

https://www.brickboard.com/FAQ/700-900/EngineOBDCodes.htm

FAQ has oodles and bundles of info joy where systems are used in 700-900 and 240. 'Tis a good read. Some iced tea with lota lemons.

There is an EGR solenoid, that is powered by the EZK ignition controller. Under the white cap is some foam to serve as an air filter, I guess, when opening and closing so dusty bits are not inhaled into the engine. Folks like Phil Machine Man here recommend some sort of poly fiber after your remove the collapsed three-decade-owld foam.

The Bosch LH-Jetronic 2.4 fuel injection control ECU is EGR enabled, yet does not control it. You may want to look at the label color of the ECU under the passenger foot well kick panel to the right of the passenger's right leg at the door hinge.

https://www.brickboard.com/FAQ/700-900/EngineFIComputer.htm

This list does not match corresponding ignition control ECUs and so is grinds my gears. The list is terribly incomplete.

In my 1991 German market 240, it has the yellow (bronze) ECU. I have a 0-280-000-946. EGR remains enabled. Though I want to remove it. to remove the EGR plumbing and sensor means a perpetual CHECK ENGINE on. You would verify ECU pinouts, and I forget whether merely extended to support EGR or you move around the wire harness wires to the ECU connectors so you have a non-EGR ECUs and have plugged the EGR exhaust manifold and EGR inatke manifold holes.

The EGR temperature sensor from the factory secures in the EGR pipe between the EGR valve outlet to the intake manifold. Replacement moves that temperature sensor to the EGR valve. The copper conductor in the wires will sometimes break after decades of vibration where the wires secure to the EGR temp sensor body. The temp sensor may be NLA.

The EGR valve itself can fail. Stuck closed or worse, stuck open. You can find new old stock or unused EGR valves on ebay and elsewhere.

EGR is a feeble attempt to reduce NOx in exhaust. EGR remains on new cars. CA, NY, German market, and elsewhere RWD Volvo are equipped with EGR.

Some of my prior posts on the topic.

Copy and paste URL:

hacking the EGR system 200 1992

https://www.brickboard.com/RWD/volvo/1627292/220/240/260/280/hacking_egr_system.html

I labeled the image incorrectly in my then haste in Spokane, WA. This is an image of the EGR solenoid.




EGR Valve Delete or substitute piping parts 700

https://www.brickboard.com/RWD/volvo/1650110/740/760/780/egr_valve_delete_substitute_piping_parts.html


EGR Temp Sensor code 4-1-3 900 1994

https://www.brickboard.com/RWD/volvo/1572807/940/960/980/V90/S90/egr_temp_sensor_code_413.html

Also, look inside the air filter box for the preheater flap valve that is stuck to hot all the time and will ruin your AMM / MAY. Remove the silver accordion air hose between the exhaust manifold heat shield and the bottom of the air filter boc under the fan shroud.


Many more articles using the search. Others can respond with better info.

Questions? Hope that help kats.

Insomnia makes me sleepy.

And now for something rather different ...

Insomnia as I'm nearly broke, worked 10 months in the last 37 months since returning to the degenerate town of my birth named toilet St. Louis that smells of an un-flushed toilet while being gang stalked and prevented from working as the secret society funded by fascist local wealthy perverts while the civilian perpetrators follow me around only to harass me for the purpose: schadenfreude.

https://en.wikipedia.org/wiki/Zersetzung

Sure, I'd like a job in WA-state, where the same happened in Spokane WA. Though with cash on hand and unused credit cards, I can't afford the move for the job in Tri-Cities WA or now Bellevue. Yet had to apply.

Jackass MO-state allows me to conceal and carry and stalking is illegal in MO-state. I'll stand my ground, again.

MO - genuine toilet.
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hi,
my 92 245 is a 50-state car with the egr and close to 190k miles. i've had no problems, but not saying it may not occur.

generally, we do not have rust issues as northern cars do, and i have no rust issues with any of the egr parts. i do have a new volvo egr pump on the shelf along with other egr parts.

my experience is different from your statement, "EGR is a feeble attempt to reduce NOx in exhaust."

i never had nox issues and always passed inspection, always. led to my thinking i wished my other 2 volvos had egr's too, but i always fixed the nox problems, anyway.

you may have a way to work around to remove the egr, but i don't like changing something that i don't have to, such as this piece of equipment. upgrading is one thing, but modifying engine emissions, etc is another. i want to avoid introducing problems.

best,
byron golden
86 245
92 245
94 940

Thanks for the reply!

First: it sounds like you need a job out in West Texas. Go make a ton of money in the oil fields, try not to keep up with your peers (i.e. do not spend every penny you make) then go back and try and make a difference in MO!
Austin is not west Texas. If you go to Austin bring your bible and bullet proof vest.

On the car: again thanks for a great reply! My gut is to just leave it intact until it becomes a problem. Then remove it. However, it does not appear that we have a good solution for re-mapping the ECU or just flat out tricking the ECU into thinking that the EGR is working or isn't needed. Is that correct?

On St. Luis. I have some friends who are doing a trauma surgery out rotation to St. Luis as you all seem to get the most of it. Ain't that a lovely quietly un-shared statistic!

Hi AndrewSpencer,

Thank you. Glad to halps. Sorry to go on so. Was hopped up on the strong black earl of grey tea.

On Volvo from the factory equipped with EGR, the ignition control ECU/ECM is equipped to monitor and control EGR as engine condition changes that include:
- warm up to normal operating temp through the ECT to activate EGR
- The EGR temp sensor through the ignition control unit (ICU) or ECU/ECM
- The sometimes called the EGR sensor on the Mitchell line-art diagrams yet is the EGR solenoid that opens and closes, exposing the EGR valve to engine air induction intake vacuum so the EGR valve opens. When open, the ICU is programmed with a threshold resistance range of the connected EGR exhaust gas temperature thermistor sensor.

The fuel injection control ECU/ECM is connected to the ICU to, I guess, receive, or maybe transceive, signals (intelligence, ho-ha!) between the two. The ICU passes EGR status to the fuel injection ECU on 240.

So, like I'd indicated, and as I want to do with my 1991 german market 240 with the same EGR as sold to the US goofy CA-state market, I'd remove the EGR piping, plug the holes, remove both EGR enabled ECUs, assess what changes at the wire harness connectors for both ECUs (and I guess as Java and JavaScript were merely) extensible, yet I'd remove the EGR wiring from the connectors, and install a set of non EGR ECUs.

Yet if you have an EGR fault code, and you do not want to remove EGR just yet, as TX-state does not care, remove and inspect the piping and clean it out as it does clog, test that the EGR valve hold vacuum as these can fail, and treat the EGR temp sensor carefully as the copper conductor inside the spirally pair of black insulated conductor will break inside the insulation at the end of the crimp on the temperature sensor bodyover time. You may be able to find spares. I'm unsure whether you can find a new positive coefficient EGR temp sensor as the system on 240 uses PTC. I'm going to guess EZK ignition on Motronic equipped Volvo is negative NTC.

EGR itself does not clog the intake on four cylinder overhead redblock. The intake manifold is rather large in diameter at the casted aluminum alloy piping whether K-Jet or your LH-Jet equipped redblock. The VW model you suggest is a more efficient air induction system. Yet either way, stuff collects inside the air induction intake. PCV can clog. Yet on Volvo EGR, the piping clogs, like I wrote, from the air intake on the way backwardthrough the EGR valve. Though on 30-year old 240, I'm more worried about the first EGR pipe between the exhaust manifold and the EGR valve inlet. These can brake and will make the engine about non-op and make for some exhaust noise. Also, the EGR valve itself can fail. So, spares are good to have of these two EGR bits.

Thank you as to the TX-state oil fields. I'd applied to dozens of jobs in petroleum to produce compliance, training, validation doc (as executable instruments) for use at the producing oil field, transfer to the distillery / refinery, and at the refinery, and to the delivery method for whole sale and retail. Though you can make bank in the oil fields, long time in direct sun and heat makes me ill. Though I guess I can do the work. I'm also an owld bassturd and as age and infirmity overtake me I may not perform well in a physically demanding role as I used to. Maybe North Dakota and the fracking fields? Who needs good drinking water?

I have a phone interview for a role in Snohomish County in lovely and mighty WA-state. The company produced applied metrology technology tools for test and measurement of a variety of systems. I'd interviewed before. Yet now I cannot afford to relocate lest the credit card companies, and I have no debt, raise the limit rather high.

Though thank you. Rather defect to Finland, Norway, Switzerland, and maybe Canada. I like a literate populous with critical notion in a real republic-like nation state and that ain't the Yoo Ess of Ayyyyy, Fonzie. Not at all. Nope.

Thanks. Hope that helps.

MacDuffy's Tavern.
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