Volvo XC90 2.4 D5 Euro 4 EGR, Cooler & Throttle Body Removal Guide How To DIY

How to remove the EGR, EGR Cooler and Throttle body on the Volvo XC90 2.4 D5 Euro 4 engine. Remove the engine cover. Remove the intake pipe for the airbox by removing the 2 8mm bolts at the front and squeezing the other end out of the airbox. Undo the jubilee clip for the MAF sensor and disconnect the wiring, to the right of the airbox there is a nut attaching the airbox to the body of the car (it's been missing on every car I've worked on). There's also a vacuum valve on the front of the airbox you can slide off the clip. You can now remove the airbox. Release the wiring harness from the side of the engine near the high pressure fuel pump and disconnect all the wiring for components nearby. Undo the jubilee clip for the throttle body and then remove the 4 8mm bolt holding the throttle body on (don't lose the gasket). Undo the pipe between the EGR and the intake manifold, this will be filthy so will benefit from a clean also. Remove the high pressure fuel pipe above the EGR with 2 15mm nuts and then you'll also need to remove the bracket on top of the EGR with 8mm bolts. Follow the cold air pip to the turbo where the MAF was removed and you'll see a 10mm bolt half way down. Also remove the jubilee clip and remove the pipe. On the side of the engine above the EGR cooler there is a 10mm bolt holding the Cooler to the block. Now you'll have a really awkward jubilee to remove from the gold pipe which is the feed from the exhaust to the EGR, I managed with a really...