I asked the Rubicon owning Service Writer about the intercooler oil issue and he now has noticed it since my last visit on another CRD, and he knows why it is happening.

So, why is it happening according to this guy? Let me guess, it is normal or harmless?

First of all this is a long time Jeep only dealer and this is a late 30 early 40 something guy who likes his Rubicon with the ARB front bumper and thinks it would be perfect with a CRD. The only diesels they see are the CRD's they sell and service. These guys can't make DC policy but if they are on your side they can help you over some of the hurdles.

He believes it is the design of the EPA required unvented crankcase, too light of oil, da du da du da. He is making no excuses for it and has no answer for it either but he will not bug me about heavier weight oil or an Old Navy trap when it is added now. That was my goal and it has been achieved.

Spent some time at a birthday party this weekend and an old logger/farmer was admiring the CRD. We had to climb all over under the hood checking it out. He has had the same problem with all of his late model Dodge pickups too. The issue didn't suprise him a bit.

Oil in the intercooler is a normal happening for all CCV (closed crankcase ventlation) systems if no filtering and oil return device is included. Unfortantly some dumb stupid engineer's think the Pressure Regulator is sufficient enough to do the trick and getting engineers & bean counters to understand that without the proper filtering system the oil will cause problems as it get into then migrates out of the intercooler system. The bean counters figure the problem will arise after warranty period.

The oil would really not be a problem if it were not for the soot created by the EGR system, once the two mix you have a real big problem on down the road at 50k plus miles. This stuf will mix and settele in behind the valves and intake ports in the head. Remove the oil and the problem with the soot becomes almost non existant, and the dust build up in the head never really causes a problem as there is no oil to cause it to stick to the walls of engine head or back side of intake valves.

With the advent of ULSD this problem will be pushed way down the road mileage wise, however it will still be a problem for long term owners. The reason being is there will always be soot in the exhuast from the burning of the fuel, just not to the same degree as in the current fuel.

As one who has had problems, both with the vehicle and the dealer, I am delighted you've had a much better experience, and expect your good experience to continue at least a half-million miles or so.

Given that oil in the blow-by gasses is the reason the EPA mandated PCV/CCV systems in the first place, only an idiot would expect there to be no such problem without a good gas/liquid separator in the line, but it seems idiots were involved somewhere here. My guess is those idiots may indeed have been bean counters, saving a few bucks on each unit weighed against problems after warranty when they turn into money makers, now don't they?

In any case, it is great to hear of someone who has a positive experience, as mostly places like this are haunted by the folks who need a bit of help for some specific problem.