A work in progress.

[euromodder]

Originally Posted by Arragonis

Is the fuel in oil thing a major issue for a Diesel ? If there is a lot of fuel in the oil do you have another issue, perhaps something worn that shouldn't be ?

Diluting the oil with fuel is a serious issue in any engine.

It reduces the oil viscosity (which was down to 75% of spec), which is especially bad when warm, and results in bad lubing, thus increased wear.

Though I don't have any previous analysis to go upon, the aluminium content in the oil is too high, and iron is way too high.
The lab doing the analysis compares it to same / similar engines in their database.

[Piwoslaw]

Bad o-rings? I dunno how else fuel could get into the oil
I've read that in our engines the membrane on the crankcase de-air-ifier (#5 in the picture below)

can start to let oil through, mucking up the intake, turbo, intercooler, manifold and all the sensors along the way (my boost pressure sensor throws a code on every longer trip, for example), but this shouldn't let fuel into the oil. Weird.

Would you like me to ask about fuel in oil at my local Peugeot forum?

[euromodder]

Originally Posted by Piwoslaw

Would you like me to ask about fuel in oil at my local Peugeot forum?

Given the very frequent DPF regenerations, these are most likely the cause.

Oil dilution with DPF is a known issue

[Piwoslaw]

I found a thread about the problem:
Fuel in oil - Peugeot-klub.pl (Google Translate)

Like you wrote, fuel in oil is caused by frequent DPF burnouts. Supposedly what happens is that during the burnout there is an extra squirt of fuel at the end of each combustion cycle to raise the temperature of the exhaust, but often this fuel is not fully burned (especially if the engine is turned off before burnout is complete) and doesn't get expelled with the exhaust. The left over fuel drips down the cylinder walls into the crankcase (or gets sqeezed in there by the high compression pressure in the cylinder). The first thing to get effected by the thinned oil is the turbine. DPF regeneration causing fuel to mix with oil used to be a trademark of VAG (VolksWagen and friends*), but PSA (Citroën+Peugeot*) is trying hard to catch up.

Replacing o-rings or other seals won't help - you have to fix the frequent burnout problem. Pug owners claim that if the regeneration cycles happen every 100km or less, then the DPF must be replaced. Though it is possible that one of the pressure sensors is malfunctioning (there are two presssure sensors in the exhaust: based on pressure before and after the DPF the ECU decides whether it is clogged*). A faulty sensor should show up on specialized diagnostic instruments, like Peugeot Planet. If you've ruled that out then maybe your ECU needs to be reprogrammed?

BTW, I not sure your Volvo does this, but in Pugs the rear window and mirror heaters turn off during regeneration to increase the load on the engine. I'm amazed at the milage you're getting despite all these problems

* - I'm sure you know this, just adding info for any lurkers

[euromodder]

Originally Posted by Piwoslaw

The first thing to get effected by the thinned oil is the turbine.

Turbine, as in turbo I'd think ?

you have to fix the frequent burnout problem.

Easier said than done, when even the dealer can't find the cause.

Pug owners claim that if the regeneration cycles happen every 100km or less, then the DPF must be replaced.

This is supposed to be a new DPF, I have only 12.000 km on it.

It was already regenerating quite frequently before replacement.
I don't know how often as I didn't keep track back then - but there's a note in my garage log here about 5 regenerations in some 900km.

It's back (or still) at that regeneration frequency despite the DPF swap.

Though it is possible that one of the pressure sensors is malfunctioning (there are two presssure sensors in the exhaust: based on pressure before and after the DPF the ECU decides whether it is clogged*). A faulty sensor should show up on specialized diagnostic instruments, like Peugeot Planet.

For a dealer, that should be something that's easy to spot, I'd think.
It's also what the service manager said it could be.

If you've ruled that out then maybe your ECU needs to be reprogrammed?

Would be lovely if they programmed the DRIVe software in it
But that probably won't be compatible.

BTW, I not sure your Volvo does this, but in Pugs the rear window and mirror heaters turn off during regeneration to increase the load on the engine.

On I guess ?
If it does so, then it doesn't show on the indicator lights in the switches nor on the dash.

I'm amazed at the milage you're getting despite all these problems

Yeah, cheers


Worst case scenario if they can't sort it out, I'll push Volvo into issuing a new Certificate of Conformity for a non-DPF vehicle, sorting the official paperwork, and removing all DPF assorted junk.

[euromodder]

The weather is getting better, and it shows !

Despite the ongoing troubles with the diesel particulate filter and the temporary removal of the grille block, I've managed to match my best fuel efficiency while commuting : 52.47 mpg .
The previous best was achieved almost exclusively on the motorway.


On smooth stretches of motorway I'm seeing instant fuel consumption figures I've never seen before, like 3.0 L/100km (78.4 mpg) @ 100 kph (62mph), and even better (81 and 84 mpg) !

Though it reads optimistically low when hypermiling, the OBC's average fuel consumption figure dropped down to 3.8 L/100km today - I haven't ever seen that before !

Remaining range + distance already covered is recording all time highs, up to and beyond 1400km (870 miles).


Pulsing less aggressively, yet coasting ever more (engine on).
Switching off the CC on overpasses (no hills around here ).


If only Volvo could get their act together and sort my DPF issues, then I can have the car eco-chipped and refit the grille block.

[Arragonis]

I got a trip average of 69.2 on the SG2 (72.3 on the on-board) to sunny Cumbernauld the other day so weather is defintely a factor.

[euromodder]

The OBC's overly optimistic readings became more realistic as I went through half a fuel tank, but I still managed to beat my previous best by 0.3 mpg !


DPF problems are still going on

[320touring]

Originally Posted by euromodder

The OBC's overly optimistic readings became more realistic as I went through half a fuel tank, but I still managed to beat my previous best by 0.3 mpg !


DPF problems are still going on

You are infinately more patient than I..

I'd just park the thing outside the dealers with a big sign in the window saying what the issue was and leave it there til they fix it!

I'd be livid if this was the level of service recieved from a dealer..

[euromodder]

Originally Posted by 320touring

You are infinately more patient than I..

With things like this, my fuse is usually a bit longer
The following explosion tends to sever things rather permanently though ...

I'd just park the thing outside the dealers with a big sign in the window saying what the issue was and leave it there til they fix it!

Not really an option when you need the car.
Unlike others around here, I don't have a pool of vehicles, just this one.

I'd be livid if this was the level of service recieved from a dealer..

It's beyond the dealer.
They were very upfront about it and don't know what's causing it.