Intermittent White Smoke S60 D5 185 Engine

[Bill_56]

Do you have the owner's manual that came with the car? Mine has a few paragraphs on the DPF, listed in the Index pages under 'diesel particulate filter'.

I think some 05 cars were Euro 3 (no DPF) and some were Euro 4 (DPF). I've been basing my assumption that you have a DPF on your opening post...:

Originally Posted by definethelight

A recent repair by my local main dealer was coupled with a free of charge 'software update' something to do with fuel re-generation...

I really can't imagine what else he'd have been talking about, other than DPF regeneration.

[Bernard333]

The 185 is definitely Euro 4 so it must have a dpf ? The 163 euro 3 D5 was supplied until sometime middle to end of 2004 then they renamed it 2.4D instead of D5 which was then badged on the 185 version only. I thought also that the 163 2.4D differed from the old D5 in that it was also Euro 4 ?

[definethelight]

Thanks for that. Yes - the manual does have a ref to the DPF. Is there any way I can tell by looking for the DPF in the engine bay - or is it part of the exhaust system. I'm sure Volvo will clarify on Tuesday morning. We shall see. Would they still have given me the upgrade for the 'regeneration' (their words) if my car was not equipped with a DPF?

[definethelight]

Another thing I noticed. The oil level is around 5mm above the max marker. Now, the car was cold (not run for a few days) when I inspected the dip stick. Perhaps the independent had slightly overfilled the oil when refilling it... Something else to keep an eye on zzzzzzzzz.

[Bill_56]

I think you've already had a look at the 'DPF recall' thread in the S60/V70/S80 area, so you'll know that rising oil level is one to watch, it's caused by diesel fuel getting into the sump. If it rises above max, Volvo have said there's a risk of the engine self-fueling, i.e continuing to accelerate in runaway mode regardless of throttle, and even after turning off ignition. I find it hard to imagine that 5mm presents any danger, but you should maybe mention it to the dealer on Tuesday.

As of earlier this year Volvo decreed that D5 cars with DPF should, when oil is changed, only be filled to 2/3 of the way between dipstick 'min and max', to allow room for some diesel too. The trouble is of course, only main dealers are likely to know that, but I guess the message will at least filter through to Volvo indie specialists.

I'm afraid I've never tried to find my DPF, so don't know what it looks like or where it is. Sorry.

[rublehousen]

Originally Posted by definethelight

Another thing I noticed. The oil level is around 5mm above the max marker. Now, the car was cold (not run for a few days) when I inspected the dip stick. Perhaps the independent had slightly overfilled the oil when refilling it... Something else to keep an eye on zzzzzzzzz.

engine oil = blue smoke. unburnt diesel = white smoke. overfuelling/dirty air filter = black smoke.

[definethelight]

Latest Update: Car was taken to Volvo main dealer today. I was open with them about using an independent specialist - and even showed them the bill itemising all the work carried out. They did point out that I would have saved a considerable sum if I'd continued to use them, as the 'unrelated' clutch master cylinder could have been replaced for half the price - due to a known 'fault'. Something about a recall. Typical. Thankfully the car smoked continuously during the road test when the tech dropped me back home. This was a 20 mile round trip - so at least they have the car in a state of 'failure'. Just have to wait and see what happens next. They insist on sending the video I took to Volvo HQ for their opinion. The coolant level looked normal, but they have an indicator liquid that they will introduce to the water jacket - this will check for leaks (possible head gasket failure). The technician's initial response was 'Faulty turbo' but will test thoroughly before replacing. Anyone know what a replacement Turbo costs? I have a nasty suspicion that this is going to cost me dearly!

[Bernard333]

The turbo for a 185 D5 is a lot different than one for a euro 3 163 bhp apart from both being variable nozzle types . The one in the attached photo is for a 185 D5 and although its not seen much use and the turbo itself is perfect the actuator has failed and its more of a headache than the previous type which used a vacuum actuator to control the nozzle , the 185 uses a stepper motor and so far I have not been able to either repair it or find a replacement actuator and even then I am advised by the boffins that it will need calibrating to the turbo so I cant just bolt one on . If it does turn out to be your turbo then for the 185 I would think its probably best dealt with by a main dealer as I cant find any aftermarket refurbers who give me any confidence that they can fix this type of unit , its another reason why I will stick with my 163 euro D5 if this is typical of the complexity of the electronics in newer models . A reasonable quality refurbed unit is £600 for the 163 D5 but they may charge a lot more if you also need the stepper type actuator .

[definethelight]

Hi Guys, This is all getting more and more interesting. Just had a call from the tech at Volvo (main dealer) asking a few more questions about the frequency off the 'smoking issue' even though he witnessed it first hand this morning. He said that he had just checked the DPF and there was only about 4-5 gms of Soot in there - Now the independent said the car pre-dated the DFP. I was Skeptical about this and didn't mention it here as I'd reat info to the contrary. The service manager at Volvo the other day said that I missed the DPF by 6 months. Now the mechanic with my car suspended in the workshop tells me that I do have one, and that he's just checked it's contents. zzzzzzzzzzzzz. Moving on, he did the same Injector Leak Off test, and found all to be even. The independent said that No.3 was leaking excessively. The Volvo chap - with no reason to doubt the independent suggests that there could be a faulty wire leading to the injector thus causing the intermittent 'leak off readings'. Aside from the injector, he enquired as to whether my car had received the latest regeneration update. I told him it had - and that it may be coincidental, but that's when my troubles started. He sounded curious, and checked the system to confirm the updates had been done. He confirmed that the car holds 6.5 ltrs of oil, and that had been revised to 5.7 ltrs to compensate for the reduced regeneration (his words). As mentioned by Bill - there is a possibility that the independent was unaware of this new specified level, and topped up to the good old max when he worked on the car last week. Volvo need to hang on to the car for further tests. They have also submitted their findings and suspicions to Volvo HQ for comment/suggestions - along with a short 'moody' video I did of the rattle and smoke from the car.

[Bill_56]

Definethelight,

Reading between the lines, it sounds like your dealer is making a genuine, and open-minded, effort to get to the bottom of things. It sounds like he's got (or at least is trying to get) the attention of Volvo Cars too. Good service, due in no small part to good diplomacy on your part, I suspect.

This is all extremely interesting, thanks for the contributions and please do keep us all up to date as the story unfolds. No chance of zzzzzz on my part. Fingers crossed you don't get landed with any more big bills. Maybe you could get them to agree to a no-fix/no-pay policy for any further expensive repair attempts?

- Bill