RandyA Posted June 24, 2017 Report Share Posted June 24, 2017 I had developed an exhaust leak. I could not pinpoint where it was. I could hear it and see the black soot covering the right side of the engine. The only way to find and fix it was to start tearing parts off. First I removed the fender liner, then the brace. To keep from cutting my leg up I removed the piece from the front with the fog and driving lights. The air filter box and piping had to come off. My add-on air horns were also in the way. This is what I had once all the parts were removed giving me access. This is where I found the leak. It was where the exhaust manifold clamped to the tube that mounts the forward EGR valve. I always thought the part that went to the EGR valve was open. It's not. I guess it is made that way for mounting and possibly heat transfer. It is all back together now. All the soot is cleaned off and and the exhaust leak is fixed. The entire job took a lot of wrenching but removing the stuff in the way rather than trying to work around it was definitely worth the time. It was not a hard job - maybe my pics and success will help another Volvo D12D owner save some shop $$$. I figure a Volvo tech would work twice as fast as I do. Since I spent a full day, including breaks and head scratchin', I figure I saved at least $450 in labor by doing it myself. That is a lot of diesel for traveling. Randy, Nancy and Oscar "The Great White" - 2004 Volvo VNL670, D12, 10-speed, converted to single axle pulling a Keystone Cambridge 5th wheel, 40', 4 slides and about 19,000# with empty tanks. ARS - WB4BZX, Electrical Engineer, Master Electrician, D.Ed., Professor Emeritus - Happily Retired! Link to comment Share on other sites More sharing options...
sclord2002 Posted June 24, 2017 Report Share Posted June 24, 2017 Randy, I need to get my truck disassembled to about the same point you did, so that I can install my OTR EGR delete kit. I think I will also have to pull the alternator off to get to an electrical connector. I sure wish we lived closer to each other so we could share some of the Volvo fun on our various projects. What is the old saying........two knuckleheads are better than one ???? Thanks for the write-up and pictures. Charlie Don't ever tell a soldier that he doesn't understand the cost of war. Link to comment Share on other sites More sharing options...
RandyA Posted June 24, 2017 Author Report Share Posted June 24, 2017 We do live next door to each other 3 months out of the year (Wickham). Maybe we can get it done this winter if you are still "working on it" Randy, Nancy and Oscar "The Great White" - 2004 Volvo VNL670, D12, 10-speed, converted to single axle pulling a Keystone Cambridge 5th wheel, 40', 4 slides and about 19,000# with empty tanks. ARS - WB4BZX, Electrical Engineer, Master Electrician, D.Ed., Professor Emeritus - Happily Retired! Link to comment Share on other sites More sharing options...
Pete Kildow Posted June 25, 2017 Report Share Posted June 25, 2017 Looks like someone put the block plug in your EGR cooler? May not be but thinking that's one of the spots . The Plugs goes to block it off. Lots of people did the plug block on the D12's back when they were new. Pete Link to comment Share on other sites More sharing options...
RandyA Posted June 27, 2017 Author Report Share Posted June 27, 2017 OK - that is interesting....... Truck belonged to a US Mail contract carrier and records show it was only serviced at a Volvo dealership until I bought it in 2009. I have no idea what the part going to the EGR valves is suppose to look like - only what mine does. I am curious as to why it was not open. Sure would like to know the answer for real. Randy, Nancy and Oscar "The Great White" - 2004 Volvo VNL670, D12, 10-speed, converted to single axle pulling a Keystone Cambridge 5th wheel, 40', 4 slides and about 19,000# with empty tanks. ARS - WB4BZX, Electrical Engineer, Master Electrician, D.Ed., Professor Emeritus - Happily Retired! Link to comment Share on other sites More sharing options...
JPL Posted June 27, 2017 Report Share Posted June 27, 2017 Randy Great way to save big bucks! You always show and tell a great repair with your pictures and words of wisdom. Keep them coming. Headed for Williamsburg (Pottery) Thursday until the 5th. I really want to look under your 5er. I'll call you. Be safe....Pat The Old Sailor Link to comment Share on other sites More sharing options...
Pete Kildow Posted July 2, 2017 Report Share Posted July 2, 2017 On 6/26/2017 at 8:58 PM, RandyA said: OK - that is interesting....... Truck belonged to a US Mail contract carrier and records show it was only serviced at a Volvo dealership until I bought it in 2009. I have no idea what the part going to the EGR valves is suppose to look like - only what mine does. I am curious as to why it was not open. Sure would like to know the answer for real. Lots of those engines has the freeze plugs installed. Also if it was done, it would also have the center knocked out of the Turbo gasket. AS its almost closed off, too add back pressure. As with the back pressure, it forces the gases back to the EGR. Would also be a box added to override the EGR program. Engines that had that done to them. Even when almost new. Pulls better, and lots better MPG. Almost like boosting the HP from 350HP to 465HP its that much difference. Link to comment Share on other sites More sharing options...
RandyA Posted July 3, 2017 Author Report Share Posted July 3, 2017 OK - have done some further pokin' around. That thing that looks like a plug put in the EGR tube is actually a valve. Yep, it opens and closes as part of the EGR action. This guy did a video on how to disassemble and clean a faulty EGR valve. Pretty interesting. Shows how it works and could save a bundle of $$$ if you have an EGR fault. Video Here. Randy, Nancy and Oscar "The Great White" - 2004 Volvo VNL670, D12, 10-speed, converted to single axle pulling a Keystone Cambridge 5th wheel, 40', 4 slides and about 19,000# with empty tanks. ARS - WB4BZX, Electrical Engineer, Master Electrician, D.Ed., Professor Emeritus - Happily Retired! Link to comment Share on other sites More sharing options...
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