EGR System Fault Tracing Checklist

Service Bulletin
Volvo Trucks North America, Inc.

Trucks
D
Greensboro, NC USA
Date Group No. Page

This Service Bulletin replaces SB 254-08, EGR System,
Fault Tracing, Checklist R, D12D (11.2004), publication 2.2006 254 08 1(24)
no. PV776-20 019416.
EGR System, Fault Tracing
Checklist R
D12D
Checklist R
W2004292
This information covers fault tracing the EGR (exhaust gas recirculation) system of the
Volvo D12D engine.
For information on the design and function of the EGR system, refer to Service
Information, group 25.
Contents
General Guide to Fault Tracing page 2
EGR System Overview page 3
EGR System, Fault Tracing page 4
Note: Information is subject to change without notice.

Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.
PV776-20047705 USA19673.ihval
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 2.2006 254 08 2(24)
General Guide to Fault Tracing
D
You must read and understand the precautions and guidelines in Service Information,
group 20, "General Safety Practices, Engine" before performing any procedure. If
you are not properly trained and certified in a procedure, ask your supervisor for
training before you perform it.
To use this checklist:
1 Complete basic data gathering

Read fault codes
Check vehicle parameters
2 Use the recommendations in appropriate symptom information, plus the

information gathered above to provide a foundation for continued fault tracing
using this checklist.
One fault often affects other systems. Therefore, it is important to confirm or

eliminate suspected causes of faults at an early stage, using tests in VCADS
Pro.
Note: For information on the design and function of the EGR system, refer to
Service Information.1
1
Impact or ID DVD: Info type "Description" group 2547
EGR System Overview
D
W2004318
A EGR valves
B EGR cooler
C Reed valves
D Mixing chamber
E Charge air cooler
F Intake Manifold
G Exhaust gases from exhaust manifold
H Main exhaust (EPG housing)
I Charge air
J Air inlet
K Cooled EGR gases
L Cooled charge air
M Charge air/exhaust gas mixture
Note: For information on the design and function of

the EGR system, refer to Service Information.2
2
Impact or ID DVD: Info type "Description" group 2547

See also:
General Guide to Fault Tracing page 2

EGR System Overview page 3
1
Vehicle Chassis Number
Check the EGR system and follow instructions in VCADS Pro.
Symptom:
Fault code present

Mileage
D Customer
Refer to:
MID 128 fault codes

1
YES NO
Incorrect value from position sensor 2
Incorrect value from temperature sensor 3, 4, 5
High temperature value from EGR temperature sensor 2, 3, 5
Incorrect EPG function 6
EGR temperature below normal 3, 4
Low Power 2, 3, 4, 6
Black smoke 2, 6
White/gray smoke 2, 5
Cracked or damaged EGR cooler brackets 7
Coolant loss 5
2 EGR Valves and Position Sensors, Checking page 6

EGR valve positions 1 and 2 display 0% (if not in EGR Cooler Cleaning mode) with coolant temperature < 65 C (149 F)?
EGR valve positions 1 and 2 display 14 3% with engine at idle, coolant temperature > 65 C (149 F)? Clutch pedal released,
and ambient temperature > -4 C (25 F), EGR Temperature > 98 C (208 F).
EGR valve positions 1 and 2 display 90 3% when activated by VCADS Pro?
ROAD TEST:
EGR valve positions 1 and 2 display 0% when under acceleration up to 1100 rpm?
EGR valve positions 1 and 2 display > 80% when engine load > 50%, engine speed > 1200 rpm, and coolant temperature
> 65 C (149 F)?
EGR valves 1 and 2 open and close properly via VCADS Pro?
EGR valve discs and seat are free from leakage when valves are closed?
Does the EGR position sensor output voltage correspond to the actual valve position?
Are checks within specifications?
Action:
3 EGR Temperature Sensor, Checking page 16

With engine cold, is EGR temperature same as ambient temperature?
With engine at normal operating temperature, is EGR temperature within normal range?
Is the EGR temperature approximately 15 C (59 F) lower after the EGR cooler cleaning test has been performed in VCADS
Pro? EGR Cooler Cleaning Test page 18
Is the intake manifold pressure within specifications? (Low intake manifold pressure can result in higher than normal EGR
2
temperatures which in turn sets a fault code.) Refer to Service information specifications for expected values and Intake
3
and Exhaust system fault tracing for troubleshooting help.
Action:
5
Vehicle Chassis Number
Reed Valves, Checking page 14

EGR reed valves are free from leakage and damage?
Action:
EGR Cooler, Checking page 20

Mileage
Is EGR cooler free from coolant leakage (internal or external leaks)?

D
Is EGR cooler free from blockage or excessive soot build-up in the exhaust gas passages?
Customer
Is EGR cooler free of corrosion in the coolant cavity and is the coolant circulating properly?
Action:
YES NO
6 EPG, Checking
Is EPG function active when engine is at idle?
EPG function deactivates when accelerator pedal is depressed?
Does EPG receive the correct air pressure at idle EGR?

4
Action: Refer to "Checklist E, Fault Tracing, EPG"
7 EGR Vibration Damper, Checking page 24
Is the vibration damper free from wear or damage?
Notes:
Completed by: Dealer: Date:
1
IMPACT or ID DVD: Info type Diagnostics, group 2841
2
IMPACT or ID-DVD: Info type Specifications group 25
3
IMPACT or ID-DVD: Info type Diagnostics, group 2500
4
IMPACT or ID-DVD: Info type Diagnostics, group 2538
D
EGR, Fault Tracing
EGR Valves and Position Sensors, Checking
WARNING
If the engine has been running prior to this check, use
caution around pipes and clamps. It is possible that
high surface temperatures can cause third degree
burns. Do not touch or handle hot components until
they have cooled sufficiently.
Note: If an active EGR fault code exists, EGR activation

cannot be performed using VCADS Pro on the faulty
valve. Possible fault codes:
MID 128 PID 27 (EGR Position Sensor 1)
MID 128 PID 362 (EGR Position Sensor 2)
MID 128 SID 146 (EGR Valve 1)
MID 128 SID 266 (EGR Valve 2)
Refer to MID 128 fault codes.3
EGR valve leakage and function check

1
If engine is cold: EGR valve leakage (valve discs) can
be checked without removing the exhaust pipes by
feeling whether the EGR pipes heat up. If engine is not
cold, proceed to step 4.
2
Start engine. With engine at ambient air temperature,
pipes should not heat up if the valves are closed properly
or are not stuck open.
Note: Perform this check only after a cold start.

Note: After EGR temperature has reached 205C (401F),
the EGR valves will open on the next 3 cold starts to
clean the EGR cooler (EGR cooler cleaning mode only)
with coolant temperature > 10C (50F).
3
Connect the PC to the vehicles diagnostic connector
and start VCADS Pro. Check that valves can be opened
and closed via VCADS Pro. Select Exhaust Gas
Recirculation Function Check and start the test. Activate
both valves and check that both pipes heat up when
valves are activated to 90%. If both valves do not function
properly, continue with next step.
3
D
4
If engine is NOT cold: Remove air filter housing and
fresh air pipe from turbocharger and air compressor.
W2003859
5
Remove EGR valve exhaust pipes between EGR cooler
and EGR valves.
WARNING
Wear appropriate eye and ear protection during this
test. Failure to do so can result in personal injury. It
is possible that debris from the exhaust can get into
eyes and ears.
With parking brake applied and transmission in neutral,

crank engine and check for exhaust leakage at the
EGR valve ports.
Note: Check with engine coolant temperature < 65 C

(149 F), EPG active, and the engine ECU does not
have the EGR cooler in the cleaning mode. At this
temperature, the EGR valve discs should be closed.
There should be no exhaust leakage at the EGR valve
ports as long as the valve discs and seats are in good
condition and a valve is not stuck.
7
EGR valve function and position checking
CAUTION
Use only VCADS Pro to activate the valves. Never
attempt to activate the EGR valves with battery
voltage; doing so will permanently damage the valves.
Activate EGR valve 1 with VCADS Pro and check the

position of valve 1.
Note: The position display should indicate 90 3%.
Note: If the valve is functioning properly, exhaust

pressure should be heard when the valve is opened.
D
8
Close EGR valve 1 with VCADS Pro and check the
position of valve 1.
Note: The position display should indicate 0%; there

should be no exhaust leakage at the EGR valve port.
Note: Turn engine OFF after check.
9
Repeat steps 6 through 8 for valve 2.
Type 1 EGR Valve

10
The illustration shown differentiates the two types of
position sensors. Motor resistance is the same on both
Type 1 and Type 2 valves.
Type 1(A) EGR valve (position sensor with

mechanical contacts) can be checked with resistance
measurement.
Type 2(B) EGR valve (position sensor without
mechanical contacts), cannot be measured with
resistance measurement (latest type).
W2005338
11
Resistance measurements
Connect breakout box 9998699 and adapter 9990014 to
EB connector ONLY and make resistance check towards
EGR motor and position sensor.
EGR Valve 1 (Type 1):
EB24 (signal) - EB17 (5 volt

Position sensor supply) = 1000 - 2200
(valve closed): EB24 (signal) - EB18 (ground) =
600 - 1100
EGR Motor EB9 - EB13 = 1 - 10

(Type 1 and 2):
EGR Valve 2 (Type 1):
EB19 (signal) - EB17 (5 volt

Position sensor supply) = 1000 - 2200
(valve closed): EB19 (signal) - EB18 (ground) =
W2005337
600 - 1100
EGR Motor EB1 - EB5 = 1 - 10

(Type 1 and 2):
If measured values are not within above ranges,

measurements should be made at 7-pin connectors at
front of wiring harness box; refer to MID 128 fault codes4
4
D
Type 1 and 2
12
Voltage Output Measurements
Connect breakout box 9998699 and adapter 9990014
between EB connector and EECU.
9998699, 9990014
W2005336
13
With the ignition key in the ON position, start the EGR
function test in VCADS Pro.
14
With engine not running and EGR valve closed (0%):
Measurement Points Correct Value

EGR Valve 1
EB24 (signal) EB 0.2 0.8 volts
18 (ground)
EGR Valve 2
18 (ground)
15
Activate the EGR valves to 90% in VCADS Pro.

EGR Valve 1
18 (ground)
EGR Valve 2
18 (ground)
Note: If you suspect that the EGR valves are not

functioning properly (or the position sensor does not
correspond to the position of the valves), the valves must
be separated from the exhaust manifold and checked
further; continue with next step.
D
16
Remove the wiring harness support bracket bolts on
top of the EGR cooler and at the rear EGR valve. Lay
bracket aside.
17
Remove the EGR valve clamps from the exhaust manifold
and separate both valves from the exhaust manifold
enough to provide access to the valve discs.
Note: Leave the coolant hose connected; it is not

necessary to drain coolant for this check.
18
WARNING
Never place fingers near the valve disc and valve seat
during testing. If the ignition key is placed in the ON
position while the valve is open, the valve disc may
close without warning and can cause personal injury.
With ignition key in ON position, activate and deactivate

EGR valve 1 using VCADS Pro. The valve should open
and close without hesitation (from 0 to 90 3%).
Note: Perform this check several times to verify the

condition of the valve and to ensure that the position
sensor displays the correct position of the valve.
19
If you suspect that the position sensor does not
correspond to the EGR valve position, measure valve
travel:
With ignition key ON, engine OFF, and EGR valve disc
closed, measure the distance from the valve seat to the
valve disc head (A) and note the value.
Output voltage when valve closed:

EGR Valve 1
18 (ground)
EGR Valve 2
W2003955
18 (ground)
D
20
Activate the EGR valve. (The position sensor should
indicate 90 3%.)
Measure the valve opening from valve seat to valve disc

head (B) and note the value.
Note: Ignition key must remain ON for this check to hold

the valve at the maximum opening during measurement.
W2003956
21
Calculate valve travel by subtracting the closed
measurement (A) from the open measurement (B).
Valve travel (B A) should be 9.3 11.3 mm (0.366
0.445 in.).
Output voltage when valve open:

EGR Valve 1
18 (ground)
EGR Valve 2
18 (ground)
22
If an active code exists and the EGR valve cannot be
activated via VCADS Pro, the valve should be checked
with the valve disconnected from the EECU and jumper
wires used to supply the position sensor with 5 volts
supply and 5 volts ground connection.
23
Disconnect 7-pin connector from the engine wiring
harness box (upper connector valve 1 and lower
connector valve 2). Connect measurement box 9998567
to the EGR valve connector only.
9998567
24
With breakout box 9998699 and adapter 9990014
connected between EB connector (upper) and EECU,
install jumper wires to tool 9998567.
9998699, 9990014, 9998567

D
25
Install 5 volt jumper wire from pin EB17 on tool 9998999
to pin 1 on tool 9998567. Install ground wire from pin
EB18 on tool 9998999 to pin 3 on tool 9998567.
Note: Make sure connection points are correct or

damage to the measurement box 9998699 could occur.
9998999, 9998567, 9998699
W2005345
26
Connect multimeter J39200 to tool 9998567. Red test
lead to pin 2 and black lead to pin 3 or engine ground.
J39200, 9998567
W2005346
27
Turn the ignition key to the ON position and check voltage
on pin 2 with tool 9998567. With valve fully closed, the
voltage should be 0.2 0.8 volts.
9998567
W2005347
D
28
Grip the valve head with suitable tool and pull the valve
disc until the valve is fully open. The voltage should read
approximately 3.8 volts.
Note: Do not open valve with a pry bar or contact

valve seat or valve face with tool, otherwise the valve
may be damaged.
W2005348
29
Check the voltage with valve open at maximum operating
opening (approximately 90%). Physically open valve
to approximately 16 mm (0.630 in) "B". Voltage should
be 2.73.7 volts.
W2003956
30
If the EGR valves are sluggish, leaking, stuck, or they do
not function properly, or the position sensor does not
correspond to the position of the valve, replace the
valve assembly; refer to Service Information, EGR
valve replacement5
Note: The EGR valves and position sensor must be
replaced as an assembly.
Note: Always replace the V-clamps and sealing rings

once they are removed. New clamps and sealing rings
are required to ensure that there is no exhaust leakage.
5
Impact or ID DVD: Info type "Repair" group 2547
D
Reed Valves, Checking
Leak Test
Possible fault codes:
MID 128 SID 281 Reed valves
Special tools: 9996662, 85105390
1
Remove EGR pipe and hose between reed valve housing
and mixing chamber.
2
Fit O-ring into connection washer 85105390 and attach
to reed valve using existing clamp.
85105390
W2004296
3
Turn reduction valve counterclockwise on pressure gauge
9996662. Open the cut-off valve and connect shop air
hose; check that the gauge is set to 0.
9996662
4
Connect pressure gauge 9996662 to connection washer
85105390.
W2004297
D
5
Slowly increase air pressure on the reduction valve until
gauge shows 100 kPa (14.5 psi). Close the cut-off valve
on the pressure gauge and observe leak-down rate.
6
If pressure drops immediately after valve is closed, this
indicates failed or damaged reed valves. Use soapy water
to verify that there is no leakage at connection washer
and EGR temperature sensor during test.
Note: The reed valves are NOT completely sealed and
some leakage is normal. However if the reed valves will
not hold any air pressure or will not build any pressure
this indicates faulty valves.
7
If reed valves are faulty, the reed valve housing must be
replaced as a complete unit. Refer to service information,
reed valve replacement6
6
IMPACT or ID-DVD: Info type Repair, group 2547
D
EGR Temperature Sensor, Checking
Possible fault codes:
MID 128 PID 412 EGR Temperature
MID 128 SID 282 EGR Cooler
Special tools: 9990014, 9998534, 9998699,
J39200
1
EGR temperature sensor function check
With engine cold, connect the VCADS Pro tool to the
vehicles diagnostic connector (if not already connected).
Select Exhaust gas recirculation function check and
start the test. Check to verify that the EGR temperature is
the same as ambient temperature.
2
If EGR temperature sensor reading is approximately
same as ambient air temperature, check the EGR
temperature function. Select "EGR cooler cleaning test"
in VCADS Pro. Engine at ambient temperature, activate
the EGR cooler cleaning, (EGR valves 1 and 2 opened
14%). With the engine idling the EGR temperature should
increase more rapidly than coolant temperature, this
indicates that the sensor is reading EGR temperature.
3
Cold engine (coolant below 65 C, 150 F): Immediately
after activating "EGR cooler, cleaner" the EGR
temperature is expected to be higher (and increasing)
than ambient and lower than coolant temperature. After
the EGR valves have been opened for a time the EGR
temperature is expected to be higher than coolant
temperature.
Warm engine: With the engine shut down for a time, the
EGR temperature is expected to be higher than ambient
and become lower than coolant temperature. When
starting the engine (and idling) with EGR active (coolant
higher than 65 C [150 F]) the EGR temperature is
expected to be higher than coolant.
4
Test drive (or perform a dyno test) and check EGR
temperature.
Note: Under normal operating conditions, the EGR

temperature should be less than 180 C (356 F),
although this value could be higher depending on ambient
temperature and heavy loads.
Note: If EGR temperature remains above 205 C (401

F) for 30 minutes, or if EGR temperature exceeds 225
C (437 F), fault code MID 128 PID 412 will be set.
Refer to MID 128 Fault Codes7.
7
D
5
EGR temperature sensor resistance check
Turn ignition switch to OFF position. Disconnect EA
(lower) and EB (upper) connectors from EECU. Attach 2
adapters 9990014 and 2 breakout boxes 9998699
to EA and EB connectors ONLY. (Measurement is
toward sensor.)
9990014, 9998699
W2005316
6
Connect DMM J39200 to breakout box sockets EB18
(ground) and EA30 (signal) and check sensor resistance.
Temperature Expected Value

10 C (50 F)
55.582 - 63.488 k

25 C (77 F)
28.182 - 31.818 k

82 C (180 F)
3.415 - 3.729 k

177 C (350 F)
295 - 355

232 C (450 F)
105 - 130
Note: The resistance values are very sensitive to

temperature.
If values are incorrect, make measurements at the 4pin
connector inside the wiring harness box.
J39200
7
Cut tie straps on engine wiring harness at air line
support bracket.
8
Remove crankcase breather hose. Remove hose from
valve cover and hose clamp on intake manifold. Pull hose
away from cable box.
9
Remove the 2 main air line support bracket bolts.
Note: This enables access to the cable box mounting

screws.
10
Remove outer cable box cover and move to the side.
D
11
Remove inner cable box panel.
12
Disconnect EGR temperature sensor connector and
connect 9998534 to the sensor only. (blue-white wire
and brown-white wire)
9998534
13
Attach DMM J39200 to test leads 1 and 2 of the 4pin
breakout harness. If values are correct, the sensor
harness should be checked from the EECU to the sensor
connector; refer to wiring diagram.
J39200
14
If sensor values are incorrect, replace the sensor. If no
fault is found with EGR temperature sensor, perform
EGR Cooler Cleaning Test page 18.
EGR Cooler Cleaning Test

Note: EGR cooler cleaning should not be required for an
engine with low engine hours or low mileage.
Preparation
1
Perform a test drive before conducting the cleaning test;
record the EGR temperature using Sensor values
history in VCADS Pro.
Note: After cooler cleaning, perform this test again to
evaluate cooler cleaning.
2
Shut down engine and allow it to cool to ambient
temperature.
Note: The engine must be cold so that condensation
will occur in the cooler.
Cleaning the EGR Cooler

1
With the PC tool connected to the vehicles diagnostic
connector, select EGR cooler cleaning test in VCADS
Pro.
Note: There is an automatic cleaning also which is
controlled by the Engine ECU. If the EGR temperature
reaches 205 C (401 F), during the next three cold
starts the EGR valves will open sooner than normal, 10
C (50 F), which creates condensation in the EGR
cooler and washes the soot out of the cooler.
2
Start engine and immediately activate EGR and EPG.
Note: EGR valves are opened 14% and the EPG is
activated with 14% air pressure.
D
3
Let the engine run at idle until engine temperature is
approximately 80 C (176 F). Let engine continue to
idle for an additional 30 minutes.
Note: Condensation occurs inside the EGR cooler during

engine heat up. This will wash soot from the cooler.
When the engine has reached operating temperature,
condensation will stop. The engine must then run at idle
with EGR valves and EPG activated for 30 minutes to
dry the interior of the EGR cooler.
4
Turn off EGR and EPG. Turn off the engine.
Evaluating the Cleaning

1
Perform a test drive after cleaning and record the EGR
temperature using Sensor values history in VCADS Pro.
2
Compare the EGR temperature before and after cleaning.
If the temperature is not approximately 15 C (59 F)
cooler, continue with Soot Check page 22.
D
EGR Cooler, Checking
Possible fault code:
MID 128 PID 111, Coolant Level Indicator.
Special tools: DBT2V700
Coolant Leak Test (Option 1)
1
Remove EGR pipe between reed valve housing and
mixer chamber.
WARNING
Do not exceed 100 kPa (14 psi) or the system may
rupture, causing serious personal injury.
Attach coolant extractor DBT2V700 to drain fitting. Apply

100 kPa (14 psi) to the cooling system.
W2004191
DANGER
Exercise caution when working around engine fan.
Cooling fan can engage without warning and cause
severe injury or death.
1 Connect VCADS Pro to the vehicles diagnostic

connector.
2 Open EGR Cooler Cleaning Test, start the engine,
and activate EGR cooler cleaning. (EGR valves will
open to approx. 13%)
For best results, make check with engine at operating
temperature. If cooler temperature is above 65 C (149
F), this check can be made without VCADS Pro.
4
With engine running and EGR valves open, check the
reed valve housing for signs of coolant mixed with
exhaust gasses.
Coolant Leak Test (Option 2)

1
Remove the air filter housing and fresh air pipe from
turbocharger and air compressor, if not already removed.
D
2
Remove exhaust pipes for EGR valve 1 and 2 between
valves and EGR cooler.
3
Check to verify that the coolant level in the cooling system
is within specifications and fill cap is securely tightened.
DANGER
Do not exceed 100 kPa (14 psi) or the system may
rupture, causing serious personal injury.
Attach coolant extractor DBT2V700 to drain fitting. Apply

100 kPa (14 psi) to the cooling system.
W2004191
5
Check for signs of coolant leaking from the rear of the
EGR cooler exhaust inlet.
Note: If leakage is discovered, replace the EGR cooler;

refer to Service Information, group 258.
8
D
Soot Check
1
Remove the air filter housing and fresh air pipe from
turbocharger and air compressor, if not already removed.
2
Remove EGR exhaust pipes between EGR valves
and EGR cooler.
3
Attach coolant extractor DBT2V700 to drain fitting and
remove the coolant from the cooling system.
4
Remove the upper radiator hose.
5
Cut tie straps loose from the wiring harness bracket on
reed valve housing and remove bracket.
6
Remove the reed valve housing outlet pipe clamp and
separate the pipe from the housing.
7
Remove damper and bracket from reed valve housing.
8
Remove mounting bolts from the reed valve housing
and pull the reed valve housing assembly away from
the EGR cooler.
Note: It is not necessary to remove the EGR temperature

sensor.
9
Shine a bright light inside rear of EGR cooler (exhaust
inlet pipes from EGR valves). Check for soot and carbon
build up inside cooler tubes. Light should be seen
through each tube.
Note: Light visible on all tubes does not mean that cooler
cleaning is not required. If there is carbon buildup in the
tubes inside the cooler, cooler efficiency will be reduced.
10
If high EGR temperature is occurring and the EGR
temperature sensor checks okay, the cooler will have
to be removed and physically cleaned; for EGR cooler
cleaning procedure, refer to Service Information, EGR
cooler replacement9.
9
D
Flow and Corrosion
1
Attach coolant extractor DBT2V700 to drain fitting and
remove coolant from cooling system.
DBT2V700
W2004191
2
Remove coolant outlet pipe between EGR cooler and
thermostat housing.
3
Using a miniature inspection mirror and light, check for
coolant corrosion inside EGR cooler that might affect
coolant flow. If corrosion is found, remove the EGR
cooler; refer to Service Information10.
Note: If corrosion is noted, check the condition of the

coolant. Replace coolant if required. (Extended life
coolant recommended)
4
Verify that coolant can flow freely through the EGR cooler
by running water through the coolant cavity.
5
If corrosion was found inside the EGR cooler, or if water
does not flow freely through the cooler, cooler efficiency
will be reduced. Clean or replace cooler as required.
10
D
EGR Vibration Damper, Checking
1
Remove the vibration damper from the bracket on
the reed valve housing.
W2005349
2
Check the condition of the damper by shaking vigorously.
If internal movement is noted, the damper is faulty
and must be replaced.
Note: The vibration damper MUST not be disassembled.

If damper is reassembled incorrectly and then reused
with a new EGR cooler, premature EGR cooler failure
may occur.
3
If no movement is noted after shaking the damper, install
the damper to the vibration damper bracket. Torque
mounting bolts to 24 Nm (18 ft-lb).

EGR System Fault Tracing Checklist

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Service Bulletin

Volvo Trucks North America, Inc.

Date Group No. Page

Note: Information is subject to change without notice.

General Guide to Fault Tracing

To use this checklist:

1 Complete basic data gathering

2 Use the recommendations in appropriate symptom information, plus the

One fault often affects other systems. Therefore, it is important to confirm or

EGR System Overview

Note: For information on the design and function of

EGR System, Fault Tracing

General Guide to Fault Tracing page 2

Check the EGR system and follow instructions in VCADS Pro.

Fault code present

MID 128 fault codes

Incorrect value from position sensor 2

Incorrect value from temperature sensor 3, 4, 5

High temperature value from EGR temperature sensor 2, 3, 5

Incorrect EPG function 6

EGR temperature below normal 3, 4

Cracked or damaged EGR cooler brackets 7

2 EGR Valves and Position Sensors, Checking page 6

EGR valve positions 1 and 2 display 90 3% when activated by VCADS Pro?

Are checks within specifications?

3 EGR Temperature Sensor, Checking page 16

Reed Valves, Checking page 14

EGR Cooler, Checking page 20

Is EGR cooler free from coolant leakage (internal or external leaks)?

Is EPG function active when engine is at idle?

EPG function deactivates when accelerator pedal is depressed?

Does EPG receive the correct air pressure at idle EGR?

7 EGR Vibration Damper, Checking page 24

Is the vibration damper free from wear or damage?

Completed by: Dealer: Date:

Note: If an active EGR fault code exists, EGR activation

MID 128 PID 362 (EGR Position Sensor 2)

MID 128 SID 146 (EGR Valve 1)

MID 128 SID 266 (EGR Valve 2)

Refer to MID 128 fault codes.3

EGR valve leakage and function check

Note: Perform this check only after a cold start.

With parking brake applied and transmission in neutral,

Note: Check with engine coolant temperature < 65 C

Activate EGR valve 1 with VCADS Pro and check the

Note: If the valve is functioning properly, exhaust

Note: The position display should indicate 0%; there

Note: Turn engine OFF after check.

Type 1 EGR Valve

Type 1(A) EGR valve (position sensor with

EGR Valve 1 (Type 1):

EB24 (signal) - EB17 (5 volt

EGR Motor EB9 - EB13 = 1 - 10

EGR Valve 2 (Type 1):

EB19 (signal) - EB17 (5 volt

EGR Motor EB1 - EB5 = 1 - 10

If measured values are not within above ranges,

Measurement Points Correct Value

Measurement Points Correct Value

Note: If you suspect that the EGR valves are not

Note: Leave the coolant hose connected; it is not

With ignition key in ON position, activate and deactivate

Note: Perform this check several times to verify the