core plug above crankshaft oil seal D5 engine

[DAMO666]

Anyone have any experience of the core plug above the rear main seal letting go? I parked up today and there was a pool of engine oil under the car, I removed the plastic cover which was absolutely dripping in oil as was the underside of the car because the drive shaft had been fligging the oil everywhere. The oil was clearly coming out of the hole in the bell housing i thought it was the main seal but there seemed to be too much oil coming out to be a weeping seal, so i rung a mate who specialises in Volvo, he told me about the core plug that can either turn or completely pop out for no apparent reason and that he had replaced 3 in the last 12 months. He also said that the new plugs from Volvo are now a different design.

Anyway time to remove the gearbox, clutch and flywheel!

[Dynosaur]

It's definitely engine oil and not clutch hydro-fluid ?

[volvo2]

Similar?

http://www.volvoforums.org.uk/showthread.php?t=93954

[DAMO666]

Originally Posted by Dynosaur

It's definitely engine oil and not clutch hydro-fluid ?

Yes certainly certainly engine oil

Originally Posted by volvo2

Similar?

http://www.volvoforums.org.uk/showthread.php?t=93954

Does sound similar but different location, mine must be a lot nearer to the sump oil level due to the amount its throwing out. I appreciate the comments about crankcase pressure causing them to be forced out, but am also curious why Volvo now supply a different design of core plug as replacement.

[zx6rman_uk]

Originally Posted by DAMO666

Anyone have any experience of the core plug above the rear main seal letting go?

Hi,

Yes this went on mine, it would go through 5l of oil in no time at all.

Cost me a few quid to get it fixed in labor, I also got the clutch replaced etc at the same time as it was already in bits.

One thing the garage had issue with was the core plug when fitted would as you say twist in it housing causing even after the reassembled to leak oil again.

[Georgey dee]

I wish I'd known about this core plug when I had my DMF, clutch and slave cylinder changed. I hear it can just pop out for no reason

I may ring and ask them if they change it everytime the box is off. I hope so. It is a main dealer.

[R-P]

I wish I had known this before I replaced my entire engine...

Well, the Volvo dealer did say it was actually the crankshaftseal, but in hindsight I'm not that convinced...

[ask]

I read a post on the forum that suggests the core plug can either turn or completely pop out for no apparent reason. Surely there must be a cause??

Well here's my issue:

I had my Volvo S80 D5 2003 serviced (routine annual service at 80k miles). Immediately on getting it back and driving home (~3miles only) it developed a MAJOR oil leak. I took the car back, and on re-examining the car at the garage, the oil was clearly coming out of the hole in the bell housing and being flung about by the flywheel.
The garage confirmed that there was NOT any leaking oil at the time they did the oil change (clearly it is now). They insist the problem has nothing to do with them or the service. They say it "must be the oil seal that is leaking" (it isn't leaking, it's poring!) ... and bizarrly they said it would leak would stop/reduce when the oil level dropped & the pressure reduced.
Eh, really... well in that case remove some oil.. (makes sense right).
Well I beg to differ!
An oil seal does not catastrophically fail instantly (or does it) and furthermore when I asked them how much oil was in the car the dip stick showed it to be ABOVE max (above max, even when it is leaking out so badly).
I personally think they overfilled the engine with oil, thereby causing too much pressure, resulting in the oil seal or core plug being blown. That's my theory.. Does that make sense? Would you tend to agree? What would be the consequences of overfilling with oil? Is there anything else that could cause a catastrophic failure/immediate leak?
Finally, is there a MUST follow procedure for oil change on a Volvo D5 2003 engine?
There are lots of questions here. Hopefully there are folks out there that can help me get to the bottom of it. I would really appreciate any advice by reply here or directly to me by e-mail: andrew.king@ntlworld.com Thank you in advance!!

[2003bhoy]

Looks like this is what happened to me last night. Clutch slipping but I managed to get it home at which point I discovered that ALL my engine all had been dumped.



Does anyone know how much it would be to get sorted and if it would be woth it on a 03 plate S60 D5 SE with 137k on it? I only really need another 6 months (18K) out of it and can't afford a new car at the minute as I am in the middle of moving house.

[Missing Lincs]

Originally Posted by ask

I personally think they overfilled the engine with oil, thereby causing too much pressure, resulting in the oil seal or core plug being blown. That's my theory.. Does that make sense? Would you tend to agree? What would be the consequences of overfilling with oil? Is there anything else that could cause a catastrophic failure/immediate leak?

Not with Volvo but I've seen several cars overfilled with oil after a service. Many garages now pump the old oil out through the filler cap instead of removing the drain plug. I don't like this method a) because they don't always get to the bottom of the sump, and b) in not doing so they leave sludge which then mixes with the fresh clean oil. Also, many drain plugs have a small magnet in them so that any metallic particles in the engine stick to it if there's any about, not a good thing to be happening but at least you can see that it is occurring from the plug.
If all the old oil isn't removed, the garage then refills with the amount as specified in there spec. book - overfilled!
I've never seen anything blow as a result, but this doesn't mean to say it won't, usually the oil gets into places it shouldn't, I've seen a small Peugeot where the whole inside of the engine bay was coated in oil - lovely mess!
Also begs the question - why don't they check the dipstick?