I had a look at this job to help out another garage who has recently joined this forum. I agreed to post a question here to help them out.

This Volvo came in with an EGR fault. The original fault code stored was P040500 EGR position sensor ciruit A. I have tested and confirmed that the position sensor of the original EGR valve had indeed gone open circuit.

A new non genuine EGR valve was fitted but it was made by the same manufacturer as the original part. All adaptions were reset using Bosch KTS but the vehicle now logs fault code P0241300 - EGR control general fault. The engine is running in limp home mode but will run correctly if the code is initially cleared and the engine started, but will return as soon as the ignition is cycled.

We're all a bit stumper as to where to look next!