sense of adventure wrote:

Do you mean egr cooler Ian?

Nope... I mean oil cooler. The EGR cooler would lead to a pressurised coolant circuit, but would not explain the oil mixed in the header tank.

Is quite a common failure on Ford Transits.


Bit more info:

[URL=]
Click image to enlarge[/URL]

Quote:

The engine is lubricated by a forced feed oil circulation system with a oil filter and oil cooler assembly.

The oil filter and oil cooler assembly is attached to the LH side of the ladder frame and consists a full-flow, disposable canister-type filter, oil cooler and oil pressure switch. The mounting plate aligns with the oil gallery in the ladder frame and is sealed by an 'O' ring.

The engine cooling system cools the oil in the oil cooler and is regulated by means of a separate thermostat, which prevents the flow of coolant through the oil cooler when the engine is cold, ensuring the engine oil warms up quickly. The thermostat opens at 75±2°C (167±35°F).

Oil is delivered to and from the oil cooler through galleries in the cylinder block. Hoses from the engine cooling system are connected to 2 pipes on the oil cooler for the supply and return of coolant.

Lubrication System Operation

Oil is drawn, via a strainer and pick-up pipe in the sump into oil pump, which has an integral pressure relief valve. The strainer in the pick-up pipe prevents any ingress of foreign particles from passing through to the inlet side of the oil pump and damaging the oil pump and restricting oil drillings. The oil pressure relief valve in the oil pump opens if the oil pressure becomes excessive and diverts oil back around the pump.

The lubrication system is designed so that a higher proportion of oil flow is directed to the cylinder block main oil gallery while a lower proportion of oil flow, (controlled by a restrictor in the oil filter housing), is directed to the engine oil cooler. The remainder of the oil flow from the outlet side of the oil filter is combined with the return flow from the oil cooler before being passed into the cylinder block main oil gallery.

The main oil gallery has drillings that direct the oil to the cylinder head and the main bearings. Cross drillings in the crankshaft main bearings carry the oil to the connecting rod big-end bearings. Oil galleries in the cylinder head carry the oil to the camshafts and the hydraulic lash adjusters.

The oil pressure switch is located in the oil filter and oil cooler mounting plate to sense the oil pressure level before the oil flow enters the main gallery in the cylinder block. A warning lamp in the instrument cluster is illuminated if low oil pressure is detected.

Oil at reduced pressure is directed towards the cylinder head via a restrictor in the cylinder block/cylinder head locating dowel. Oil then passes through a drilling in the cylinder head to the camshaft carrier, where it is directed via separate galleries to the camshaft bearings and hydraulic tappet housings. Return oil from the cylinder head drains into the sump via the cylinder head bolt passages.

Ian

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated  IRB
The home of the first modified Keswick Green 90 - and the first 2.4 Puma through both the 200bhp and 550Nm barriers.

www.IRBdevelopments.com

www.facebook.com/irbdevelopments

www.integrated316.com

www.facebook.com/integrated316

RichieRich wrote:

Thanks Ian for very informative reply! The mechanic had us stand well back when testing the injectors out of the engine!! Interesting that you mentioned the oil cooler, discovered that issue when researching online but one of the problems over here is lack of experience with the mechanics. Temp gauge to the red, limp mode, oil in water tank they automatically presume the head gasket! So that has now been replaced but must check to see if the oil cooler is faulty!

I don't think the mechanics over here have the tools to reprogramme anything on a Land Rover so that's going to be a massive issue!!

Not sure how serious you are about a weekend in Cape Verde (might need to be a week though due to flights) but we've had enough of Cape Verde mechanics and don't trust they won't actually do more harm than good when working on the car so we are seriously thinking about flying over an expert from the UK!! If this is something you would be interested in I can email you more info!?

Wish we'd bought a Hilux now!!!!

Cheers

Richard