Technical DPF regeneration failed.

[Golonko]

I'm at a loss overall but some things/clarifications come to mind.

Did the new DPF have at least a couple of smoke free regens after it was installed, or was it also smoky from the start?

This thing about the dashboard resetting -- is there more than the messages you'd get if you manually disabled the cruise control?

Is your oil level going down?

Is the reconditioned engine the same type as the one before?

What I can offer is if you record a regen attempt with the speed, rpm, instant fuel consumption, differential pressure, DPF temperature I can try to match that next time mine is due and we can compare the data. Ideally with some normal driving before.

Looking at your graphs again, your DPF is quite blocked and the soot load should be way above 100%. Do you have a longer recording?eplace

In the first regeneration with new DPF there was a very low smoke. In the followings more smoke but not so before replacing.
Yes, the oil level is going down. Now i have to replace the PCV valve, because is passing oil to the intake (second time replaced with the new engine).
I can't export my recordings. I use Ediag app.
I had the same regeneration problema before replacing the engine. Replacing the inyectors became crazy, triggering to have to get a new engine.

 

[lycopersicum]

There's a document from FIAT listing possible causes of DPF malfunction:

1 - Incorrect thermostat operation
2 - Incorrect flow meter reading
3 - Incorrect injection operation
4 - Presence of oil in intake circuit
5 - Turbo compressor problems
6 - EGR valve problems
7 - Condensation
8 - Oil leakage from valve guides

On 3 (injectors) it says:
high particulate production-regeneration cannot be run.
- check correspondence between IMA injector codes and injector codes written in ECU.
- try to reset self-learnt injection amount.
- replace the injectors.

4 seems relevant given you have an issue with oil in the intake.

On 6, EGR valve --
The EGR valve problems are the most difficult to diagnose.
Faults of this component will cause high smokiness and as in the other cases, incoherent CCM data and consequent lighting of the engine warning light (MIL) and the generation of fault code P1206.
In the most severe cases, the ECU has an internal diagnostic procedure with the generation of a specific error code.
The faults of this component are not easy to diagnose in the least severe cases. Replacement is therefore recommended.

 

[lycopersicum]

This would be my current theory:
- the smoke and high temperature are "normal" when trying to regen a DPF with heavy soot load.
- the dashboard glitch is "normal" when a regen attempt gets interrupted.
- the regen gets interrupted when the pressure goes too high during the regen. This is why driving gently sometimes works.
- regen attempts at 85% soot load indicate that the ECU is confused about the state of the DPF. The ECU thinks the soot load is low but the pressure sensor says it is high. The regens keep happening too late.

Why the mismatch?

- either because the mechanic failed to reset the soot load with the new DPF, but this should have "self-corrected" after the first regen

- or because the exhaust contains abnormally high soot, so the DPF is filling up faster than normal

- the root cause for the high soot production could be any of the 8 things listed in the previous post.

 

[Golonko]

There's a document from FIAT listing possible causes of DPF malfunction:

1 - Incorrect thermostat operation
2 - Incorrect flow meter reading
3 - Incorrect injection operation
4 - Presence of oil in intake circuit
5 - Turbo compressor problems
6 - EGR valve problems
7 - Condensation
8 - Oil leakage from valve guides

On 3 (injectors) it says:
high particulate production-regeneration cannot be run.
- check correspondence between IMA injector codes and injector codes written in ECU.
- try to reset self-learnt injection amount.
- replace the injectors.

4 seems relevant given you have an issue with oil in the intake.

On 6, EGR valve --
The EGR valve problems are the most difficult to diagnose.
Faults of this component will cause high smokiness and as in the other cases, incoherent CCM data and consequent lighting of the engine warning light (MIL) and the generation of fault code P1206.
In the most severe cases, the ECU has an internal diagnostic procedure with the generation of a specific error code.
The faults of this component are not easy to diagnose in the least severe cases. Replacement is therefore recommended.

I'm trying for a new garage. Because mine is not interested in waste enough time to find the problem... I'm looking for a Fiat official garage but they don't want campers. They do not accept campers directly or when I say it's a camper, they give for three months.
In the meantime i'm going to try by myself something regarding the problem of oil in the intake. I'm going to unplugg the tube from PCV valve avoiding to enter oil from the engine to the intake. So it's going to have always clean air and maybe get a better regeneration. Just for try.