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I may have done a bad thing 900 1994

posted by Raptop on Thu Apr 21 20:57 CST 2005
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last visit: Sat Apr 16 23:45 CST 2011

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I am in the midst of replacing my oil trap (aka breather box), and of course to do so requires the removal of the EGR valve. In the process of loosening the EGR inlet (from the exhaust side) I totally stripped the thread off the back of the EGR valve.

Will I need a new EGR valve? Or can that compression fitting come off and be replaced?

I started to put it back together in the hopes that there might be enough thread beyond the stripped portion to get a hold of, but alas, no joy.

Advice apprecitaed, TIA

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EGR valve replacement 900 1994

posted by miracleman49 on Sun Apr 24 01:36 CST 2005
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last visit: Wed Apr 6 15:53 CST 2011

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I once attempted removing/cleaning breather box on 91 240. After tinkering with EGR valve for a while, I abandoned my plans and reassembled everything. It is a royal PITA!!!

I later posted for advice and got a couple emails. I was told that unless your state has a vehicle inspection program, and specifically checks your EGR, a person could legally remove the EGR system with no ill effects to the engine.

Caveat: I an NOT suggesting, encouraging or endorsing such action. This post only meant to share my experience in gathering EGR info and assistance. My personal advice is to mortgage your home and take the car to a Volvo dealer.

Good luck with your EGR dilemma.

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EGR valve replacement 900 1994

posted by Raptop on Mon Apr 25 22:59 CST 2005
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last visit: Sat Apr 16 23:45 CST 2011

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I've actually considered that. I live in Hawaii, and they do not test for emissions. They pretty much just make sure the tail lights work.

Now I'm re-considering.....

Is it ethical?

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EGR valve 900 1994

posted by Peter Penguin on Sat Apr 23 02:48 CST 2005
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last visit: Mon Oct 13 08:59 CST 2014

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Well first off... congratulations on getting the EGR valve off!

I too have the EGR valve and I've scoured the Brickboard for hours and hours looking to find any information about them, and came away with very little or none.

It's a total design flaw to have the damn EGR valve sitting right over the bolt on the breather box, imho.

Anyhow, I think that connection needs to be secure, since the gases inside are under pressure no doubt. Why not take the part to a machine shop and see if they can do anything about fixing the threads?

That's what I'd recommend.

Otherwise, buying a new EGR might not be a bad idea, since once you get that thing back in again, you don't want to mess with it ever again for the life of the car.... it's such a total pain.

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EGR valve 900 1994

posted by Raptop on Sat Apr 23 10:43 CST 2005
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last visit: Sat Apr 16 23:45 CST 2011

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I actually couldn't loosen the nut that holds the EGR valve on its bracket, but in wrenching so hard on it, I twisted the bracket itself which took the EGR valve out of the way. Then I could the 2 bolts that hold the EGR bracket (they also hold the oil trap).

I thought about trying to re-tap some threads on there, but they are sheared clean off. I don't know for sure, but I'm guessing they are still lodged in the compression nut, meaning I'll need a new inlet pipe. (It's a flare-type tube, and the nut won't come off so I can re-tap it).

As long as a new EGR valve isn't ridiculously expensive, I'm going to replace it. But alas, the parts dept at the dealer only works M-F.

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EGR valve 900 1994

posted by Peter Penguin on Sat Apr 23 12:34 CST 2005
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last visit: Mon Oct 13 08:59 CST 2014

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No doubt if you have to go to a volvo dealer parts department, it'll cost more than a place like Swedish Engineering online. That place seems to have every part in the car. They have a west coast distribution office now along with their main store in georgia.

Good luck... hope it all gets put back together without too much trouble.

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EGR valve 900 1994

posted by Peter Penguin on Sat Apr 23 12:37 CST 2005
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last visit: Mon Oct 13 08:59 CST 2014

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I don't know if the 240 had an EGR valve in the latter years, but you might try posting something there too. Make sure you put the subject 'EGR Valve' in the heading... so that interested mechanics online will open that message.

It's a very rare part of the volvo engine... since I think they were mostly made for California cars.

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