A work in progress.

[euromodder]

Originally Posted by Piwoslaw

A pre-turbo leak shouldn't make too much of a difference

That extra air won't be measured though, and would throw off the mix.
"False air" being drawn in is a know cause of trouble.

Combined with the post-turbo loss, the ECU was simply being fooled about what amount of air and % EGR it had.

while post-turbo should lower boost pressure.

And cause excessive EGR (= more soot), less overall efficiency, less power, leading to more throttle and more diesel being used.

Calculated engine load on the SG is around 10-15% lower now.
I can do 120 with AC @ a loading I got doing 100 without AC before.
LOD translates directly in fuel use.

I remember reading somewhere that one of the things PSA did in the new 1.6 e-HDi is to seal up the air doser (between turbo and intake manifold) to make it less leaky.

You mean the Y-shaped fresh air / EGR butterfly valves assembly ?
There shouldn't be any leaks there at all.

Maybe they meant making it less prone to leaking ?
Or reduce the internal leaky-ness of the valves ?
The valves' operating mechanism isn't really smartly designed, with plastic parts wearing out easily, affecting air and EGR.

OK, here I am making smart comments, while you get a born-again car tune-up to go and leave my fuel consumption in the dust!

Don't worry, I'll have a hard time beating your 3.66 L/100km

[Arragonis]

Glad it seems better, should be interesting to watch.

Are these Volvo parts or PSA ones as they are more engine rather than car model related?

I'm having to re-learn driving petrol . Fuel of the devil it is, mark my words...

[Piwoslaw]

Originally Posted by euromodder

That extra air won't be measured though, and would throw off the mix.
"False air" being drawn in is a know cause of trouble.

Combined with the post-turbo loss, the ECU was simply being fooled about what amount of air and % EGR it had.

Ah, so the leak was between the sensor and the turbo? That would explain it.
My air sensor combo also has a metal screen, but only on one side (upstream of the sensor). I believe that the metal screen may be heated, but I'm not sure of this. I haven't noticed oil on it, but I haven't looked lately.

Originally Posted by euromodder

You mean the Y-shaped fresh air / EGR butterfly valves assembly ?
There shouldn't be any leaks there at all.

Maybe they meant making it less prone to leaking ?
Or reduce the internal leaky-ness of the valves ?
The valves' operating mechanism isn't really smartly designed, with plastic parts wearing out easily, affecting air and EGR.

I meant the intercooler bypass valve (air doser, "butterfly double air metering device"). They come in different shapes and configurations, some only restrict the intake, others allow the IC to be partially or completely bypassed. Not sure which one you have? But the EGR comes in later, in the intake manifold, after the air doser. The way that the air doser can increase EGR flow is by partially restricting the intake (=lowering air pressure) before the EGR inlet.

Could you post a picture or 2 of your "naked" engine (sans plastic covers), and maybe show which parts went bad? I don't suppose you have a picture of the cracks and holes in the replaced parts?

Originally Posted by euromodder

Don't worry, I'll have a hard time beating your 3.66 L/100km

Don't worry, I probably won't get any chances to beat that again for a long time

Originally Posted by Arragonis

I'm having to re-learn driving petrol . Fuel of the devil it is, mark my words...

I thought diesel was the devil's fuel? Sulphur, smoke, and all that.

[320touring]

Originally Posted by Arragonis

Glad it seems better, should be interesting to watch.

Are these Volvo parts or PSA ones as they are more engine rather than car model related?

I'm having to re-learn driving petrol . Fuel of the devil it is, mark my words...

it is interesting to note that it does appear to have been a fault with the car rather than driving sttyle- so you're doing nothing wrong, euromodder

The only thing I can think of is, does the ecomodding style of driving cause the engine to spend lots of time operating outwith the mapping profie for the ECU ?

I'm thinking of things like long periods at idle (e.g. E(on)C)

Certainly My Scaab didnt seem to take particularly kindly to that particular persuit, although it did return good figures!

What I'm getting at is this- did your endeavours to get better MPG have a detrimental effect on the longevity of the components?

Certainly my NA 318iS seems happier than the turbo Scaab with em using the same techniques and thier Cd and CC of engines are similar

[320touring]

oh, and Arragonis- Petrol FTW

[sarcasm]Throttle respone is such a pain to live with..[/sarcasm]

[euromodder]

The tank from hell is in.
@ 5.92 L/100km - 39.7 mpg(US) it's not too bad.
It's what I used to get some years ago, before slowing down - and I've seen worse

The dealership went through nearly 2/3 of the tank for half the miles.
I used the other 1/3 for the other half - even though I haven't really been hypermiling it.
Actually, it's been doing higher speeds (legal limit), higher rpm than the last year.


The DPF was renewed somewhere around 146500-146600 km.
The first regeneration was at 146987.
The next one a mere 238km later at 147225 - far too quickly. Again.
I'll see what happens on this full tank, but it looks like Hägar isn't cured.

I've just about had it with this car.

Originally Posted by 320touring

it is interesting to note that it does appear to have been a fault with the car rather than driving sttyle- so you're doing nothing wrong, euromodder

The frequent regenerations happen regardless of whether it's been hypermiled or not.

I'm thinking of things like long periods at idle (e.g. E(on)C)

I'm idling while coasting, but otherwise, when the engine is warm I'm idling less than many people.

What I'm getting at is this- did your endeavours to get better MPG have a detrimental effect on the longevity of the components?

Definitely not on the air intake tubing, that's not affected by driving style

[Arragonis]

I'm getting more used to not waiting for the turbo to kick in - because there isn't one.

My main puzzlement is what affect throttle position has on MPG, it isn't as linear as it was with the TDI - but that is something for the George thread. I have popcorn waiting for the first Hypermiling tank for the 6 million dollar Ovlov - they had the techology, they rebuilt him...

[euromodder]

Originally Posted by euromodder

The DPF was renewed somewhere around 146500-146600 km.
The first regeneration was at 146987.
The next one a mere 238km later at 147225 - far too quickly. Again.
I'll see what happens on this full tank, but it looks like Hägar isn't cured

Next regeneration: 241 km after the start of the previous one.

[Piwoslaw]

Originally Posted by euromodder

Next regeneration: 241 km after the start of the previous one.

Looks like Hägar is going back to Dr Volvo...

[Arragonis]

Is the oil level elevated ?