HELP!! need some advice constant regen from transit mk 7 2.2

[YellowVMan]

My Friend has asked me to post as we are all out of ideas.

transit 2.2 stock engine has about 140 bhp, his has 189 bhp, 14 plate FWD.

Before I start. The van has been in the garage twice in the last few weeks. 4 hours of diagnostics and a replaced EGR motor as that was making a loud noise. Regens ever 55-60 miles.

1 DPF not blocked, within range 3 millibar or something like that.
2 Engine temp fine.
3 injectors fine but one is slightly higher than the rest but still within tolerance
4 No fault codes apart from a communication issues from the alternator to the ECU. charging as normal
5 The engine has had dpf issues since 5000 miles, previous owner broke down in france with a pressure sensor switch and again at 8000 miles. he bought it at 11k miles and the regen has been odd and the last 2 years regens have become more of an issue.
6 engine was remapped on dyno and they too have issues with it regeneration while on the dyno
7 Oil level rises in the engine only in the winter months!!!

The garages are at a loss, took the van out and it started to regen where the exhaust sounds like a jet taking off under power. We feel, why its making such a loud nose is the fuel being burnt in the dpf is passing through as its not blocked causing the jet engine sound, that will last a few minutes, it was on the diagnostic while regen was in progress but nothing showed up.

The engine just a few miles before it starts to regen will sound odd, like a lawn mower with no power and no torque but straight after regen it will pump full power and sound like a diesel again.

The guys in garage called his mate who deals with dpfs more than them and he said it may be a fault ecu? and then sound it may not be a regen but a something else causing it.

The engine never brakes down, always starts and pulls very well until it regens. es going to take it to ford but doesn't fancy the cost

ODDLY the diagnostics isn't showing when the engine last did a regen??? and when its regenning it seems to go into limp home mode, limits speed to 45 mph.

HELP please?

Chris.

[tranmx2]

7 Oil level rises in the engine only in the winter months!!!

Damaged head gasket, crack in block. Engine hot, oil and coolant vapour, emulsion, passes to inlet system to combustion spaces where it is not burnt off. Passes to DPF which partially blocks, D DPF sets of regen.
600C at DPF likely sufficient to burn off emulsion.
Gundge in inlet system can slieau off and pass to DPF.

Exhaust temp about 300C, regen after vapouriser 600 C.

See ORiley DPF youtube.