1992 Volvo 240 GL, StandardFACTORY OEM SERVICE PROCEDURE

Code 1-5-4 (Egr Flow Too High)

  1. Check engine idling. If engine idles unevenly, go to next step. If engine idles evenly, go to step 5).
  2. Disconnect harness electrical connector from EGR vacuum controller. If idle is still uneven, go to next step. If engine idles evenly when connector is disconnected, check wiring between control module and EGR vacuum controller for short to ground. Repair as necessary. See WIRING DIAGRAMS section.
  3. With engine idling, CAREFULLY remove yellow vacuum hose from EGR vacuum controller. If engine now idles evenly, install new EGR vacuum controller and retest. If engine still idles unevenly, go to next step.
  4. With engine idling, CAREFULLY remove yellow hose at EGR valve. If engine now idles evenly, hose is obstructed. Replace hose and retest. If engine still idles unevenly, install new EGR valve and retest.
  5. Check engine temperature. Verify that temperature rises to normal range smoothly, and that upper radiator hose is hot when temperature stabilizes. If the above conditions are not observed, install new thermostat and retest. If engine temperature control is normal, go to next step.
  6. Turn ignition OFF. Clean EGR and ECT connectors and treat for corrosion, if necessary. Remove, clean, and reinstall ground wire at intake manifold
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.