2005 S80 2.5T 5Cyl Excessive Oil intercooler, Faulty PCV

[Volvo_CV]

Hi,

I have been having an issue with my 2005 Volvo S80 2.5T 5 Cylinder FWD. I had the engine replaced due to a catastrophic failure due to oil loss at 100,000 miles. The new engine had 103,000 miles, and after a year of driving it is at 113,000 miles. The new engine set-up has been losing oil excessively without leaving oil in my parking spot. There are three separate issues I outline below, and I am asking for your advice on how to go about correcting these problems.

If the images are not working below, they are also available here:

http://imgur.com/a/GG2cj#0

There appears to be an excess of oil in the intercooler system (pictured below, (1) collected in the lower elbow of a hose, and (2) coating the inside of a hose.





In addition to the intercooler problem, the PCV system appears to be faulty as well. I had smoke coming out of the dipstick tube, and oil cap. After attaching a glove to both, they were not sucked in, but flapped about at idle, and after revving the engine to 2000 rpm. To access the PCV system, I have removed the intake manifold as pictured below.



Also, there is a build up of sludge and oil next to the passenger side wheel well, as pictured below. I don't know too much about cars so I don't know what to think of this.




There is oil spatter and sludge all around this region, and I pulled off this rubber part that I also took a picture of below, because I was not sure what I was looking at.







I was not aware I was burning/losing oil until 3,000 miles after my last oil change. I filled the engine with an additional 4 quarts of oil, overfilling it by a quart, and drove 300 miles home for Winter break. Since then, the car has been burning oil to an extent that it is smoking and coming into the car through the lower vents. I'm not really sure what I'm dealing with, and I wanted to do my own maintenance on the car. Right now I have it up on stands with all the oil drained.

What do you all think of this situation? Do you know what could be going on with my car? Any advice or links to more information would be appreciated thanks, I will follow up on how the repair goes.

[difflock54]

Overfilling your engine with oil by 4 quarts is likely the main reason your currently burning oil.
That is a huge excess for the motor to handle. It's drowning in the stuff.
If the glove test is showing no suction but lying limply it would appear your PCV system is probably in need of a service and is clogged up.
Given the above re the PCV it is most likely you have blown out a number of your oil seals in the engine hence all the mess everywhere.
Suggest you remove the plastic timing cover and look at the front cam seals and the front crank seal also for evidence of oil leakage. If your rear main seal has gone too then you would have to pull the motor to fix that with the transmission removed to access it.
Oil spraying about in the timing cover will damage the timing belt and it could snap so do not drive about if leaks are in that area. The rear camseals if leaking at the opposite end will show too especially with the distributor removed.
Check for oil ponding around your spark plugs in the recesses and under the centre top camcover.
From your pics it looks like the PCV oil trap and the shiny hose clips are fairly new or the system has been serviced not long back, however the glove test will prove otherwise if you are not getting the suction as you should.
Investigate thoroughly to locate all your leak sources, dont guess as it gets expensive when your wrong.

[Volvo_CV]

Sorry but I should clarify, I added 4 quarts when it was low at the time I checked it, as it appeared that it was 4 quarts low on oill. Checking the oil level after I filled it, I realized I overestimated, and it was about a quart over. I'll remove the timing cover and take a look thanks. I'm hoping the rear main seal is alright. Thanks for the advice I'll get back with more pics

[volvos80forlife]

now my pcv breather hose broke off..but i managed to glued it back together. can i just change the hose.

[difflock54]

Replacing that 1 hose would be ok if the system was confirmed as operating correctly however given that it appears likely you need to do work on your PCV system, replacing that single breather tube would not solve your problem long term.
If 1 hose/tube is brittle and breaking then others may be in a similar condition and will soon give trouble.
The camcover breather tube connects to the top of the PCV oil trap anyway so to replace it requires you to remove the inlet manifold, at which point your basically in there to do a complete service on the system anyway.

[volvos80forlife]

ok so i changed that hose since i did not want to drive with broken hose. so far no problems and no smoke. but ya you are write i will have to get the pcv serviced. but i think i will wait for sometime.