D5 (D5244T to 2005) Grey oil in Intercooler outlet hose :O

[TimFromNorway]

Good evening fellas

Just changed all of my intake and outlet hosing to silicone hoses from do88.se and noticed something that made my heart stop for a second. When I removed the CAC (charged air cooler) outlet hose, the one that goes to the EGR mixer, about half a deciliter of grey oil began to drip out. Anyone seen similar on their D5s? BTW, its an 2003 D5244T V70, with an aftermarket CAC fitted, as the original split. This CAC was bought from do88.se and is 100% aluminum.

I've been really pedantic about my oil changes, changing about every 8000KM, simultaneously changing all filters too, both air and oil. The oil that comes out have been black everytime with no metallic residues, just plane, used oil. Is my baby in pain or is this normal? Last time I changed the oil, I used Castrol's EDGE A3/B4 fully synthetic with Titanium FST, could this be the issue?

Appreciate all ideas and answers

Best regards, Tim

[cheshired5]

What is a CAC outlet hose?

[TimFromNorway]

Originally Posted by cheshired5

What is a CAC outlet hose?

Charged Air Cooler outlet hose, the one that goes to the EGR mixer

[cheshired5]

Oil in that hose is very common.

[5cilinder]

Its oilvapor from the crankcaseventilation wich is condensed and trapped in the cooler

[TimFromNorway]

Originally Posted by 5cilinder

Its oilvapor from the crankcaseventilation wich is condensed and trapped in the cooler

So it's nothing to worry about? I know that some oil is normal, the color of it is what scared me most, it's like someone took a handful of clay and mixed it in.

[5cilinder]

Its not only oil , its also mixed with condensed watervapor/exhaust/crankcase carbon fumes and a bit of dirt
Nothing to worry about if its not liters all intercoolers have this because its inherent of the systemdesign vapor gets cooled and some condenses and get trapped there

[skyship007]

Originally Posted by TimFromNorway

Good evening fellas
Just changed all of my intake and outlet hosing to silicone hoses from do88.se and noticed something that made my heart stop for a second. When I removed the CAC (charged air cooler) outlet hose, the one that goes to the EGR mixer, about half a deciliter of grey oil began to drip out. Anyone seen similar on their D5s? BTW, its an 2003 D5244T V70, with an aftermarket CAC fitted, as the original split. This CAC was bought from do88.se and is 100% aluminum.
I've been really pedantic about my oil changes, changing about every 8000KM, simultaneously changing all filters too, both air and oil. The oil that comes out have been black everytime with no metallic residues, just plane, used oil. Is my baby in pain or is this normal? Last time I changed the oil, I used Castrol's EDGE A3/B4 fully synthetic with Titanium FST, could this be the issue?
Appreciate all ideas and answers
Best regards, Tim

Not sure how much half a deciliter is, but it does not sound enough to be an issue, although I would check the dipstick for signs of Mayo, just in case the HG is starting to fail.
Traces of emulsified oil, OR emulsified half burnt diesel fuel are normal in the CCV and exhaust bypass system if a diesel does not get enough Sunday morning motorway WOT to cook off the water.

The Volvo dealers in Germany use Castrol Edge 0w40 (Acea A3/B4) in older cars, although they use Edge 0w30 in newer Volvo's that are still under warranty. The use of those expensive oils will have nothing to do with the Mayo formation.

Changing the engine oil too often does not do any real harm (Complex subject as you can only figure out the ideal change interval from used oil analysis and every engine block is different), BUT changing OEM standard air and oil filters sure does. A new air or oil filter will let between 5 to 10 times the amount of debris past it that an older filter that is nearly blocked will, so it's best not to change an oil filter until the maximum recommended interval.

The air filter can be inspected every oil change and changed on condition. A real dirty air filter can stop 99.8% of 20 micron dust particles, but a new one might only stop 98%. That means the new one is letting ten times as much debris into the engine as an old one (2% vs 0.2%).

The same efficiency game applies to fuel filters, BUT I have known old full ones split, so it's not worth exceeding the Volvo recommended change interval just because it looks clean, as fuel standards vary and the consequences of a failed fuel filter are real bad news.

I don't know what you are paying for Castrol Edge FST, but like Mobil 1 0w40, it's only a HC (Hydro Crack) synthetic and not as good an oil as either Shell Ultra or Liqui Moly Synthoil, as Ultra uses a base stock made from natural gas and Synthoil is a true German standard full synthetic made in a chemical plant. Shell own Penzoil in the USA and their Ultra Euro (Same mix as the Shell Ultra) has a real cult following, as it produces real good UOA results and cleans up old blocks far better than anything Mobil or Castrol make:
http://synthetics.pennzoil.com/#cleanest-pistons

[Cantankerous One]

Originally Posted by skyship007

Not sure how much half a deciliter is .......

I think it would be 50ml as a decilitre is 100ml (deci = tenth)

[TimFromNorway]

Originally Posted by 5cilinder

Its not only oil , its also mixed with condensed watervapor/exhaust/crankcase carbon fumes and a bit of dirt
Nothing to worry about if its not liters all intercoolers have this because its inherent of the systemdesign vapor gets cooled and some condenses and get trapped there

I see Would it be beneficial to flush the intercooler once in a while to get rid of these residues?

Originally Posted by skyship007

Not sure how much half a deciliter is, but it does not sound enough to be an issue, although I would check the dipstick for signs of Mayo, just in case the HG is starting to fail.
Traces of emulsified oil, OR emulsified half burnt diesel fuel are normal in the CCV and exhaust bypass system if a diesel does not get enough Sunday morning motorway WOT to cook off the water.

The Volvo dealers in Germany use Castrol Edge 0w40 (Acea A3/B4) in older cars, although they use Edge 0w30 in newer Volvo's that are still under warranty. The use of those expensive oils will have nothing to do with the Mayo formation.

Changing the engine oil too often does not do any real harm (Complex subject as you can only figure out the ideal change interval from used oil analysis and every engine block is different), BUT changing OEM standard air and oil filters sure does. A new air or oil filter will let between 5 to 10 times the amount of debris past it that an older filter that is nearly blocked will, so it's best not to change an oil filter until the maximum recommended interval.

The air filter can be inspected every oil change and changed on condition. A real dirty air filter can stop 99.8% of 20 micron dust particles, but a new one might only stop 98%. That means the new one is letting ten times as much debris into the engine as an old one (2% vs 0.2%).

The same efficiency game applies to fuel filters, BUT I have known old full ones split, so it's not worth exceeding the Volvo recommended change interval just because it looks clean, as fuel standards vary and the consequences of a failed fuel filter are real bad news.

I don't know what you are paying for Castrol Edge FST, but like Mobil 1 0w40, it's only a HC (Hydro Crack) synthetic and not as good an oil as either Shell Ultra or Liqui Moly Synthoil, as Ultra uses a base stock made from natural gas and Synthoil is a true German standard full synthetic made in a chemical plant. Shell own Penzoil in the USA and their Ultra Euro (Same mix as the Shell Ultra) has a real cult following, as it produces real good UOA results and cleans up old blocks far better than anything Mobil or Castrol make:
http://synthetics.pennzoil.com/#cleanest-pistons

Thank you for this information, I will surely take it with me the next time I do a service. Always thought that new is better, therefore I always changed everything in one go.

As for the dipstick, I checked it today, no mayo, just plain clear oil

But regarding the oil filter, this shouldn't be changed everytime I change oil? I don't know Volvo's intervals when it comes to changing oil, but I drive pretty long stretches over one year, including really ****ty roads full of gravel and dust, therefore I usually change the oil 2 times a year, every 8000KM or so.