D2 Td5 oily cooling system

**justinc** · 25th July 2009, 07:34 PM

Just had a D2 Td5 with oil in the cooling system, low km (130k) and had recently had a head gasket replaced due to failure 12months ago in Vic. I wasn't able to find out what the symptoms were in the first place, but 12months later the system is still oily and all the hoses are ruined. My first thought was flush it a few more times and recheck, considering it takes a LOT of cleaning to remove oily sludge and it may not have been done enough . Wrong. After 500km it was worse, not better. Still at this stage suspecting the head possibly for cracking etc, BUT oil cooler is a common enough failure point but rare at such low KM/ age. So I thought. After removing the cooler it was absolutely pitted, electrolysis was chronic, BUT pumped 100psi through it under water and no leaks

Orings still soft but crushed a fair bit, IE very little protrusion, so inconclusive in my books. Fitted a new cooler, all cooling system hoses, flushed 4 times with a detergent solution, and today driven 200km and flushed again. Looks good so will keep an eye on it.
Interestingly, the cooler element didn't look like it was leaking, BUT if I was to suspect anything it would be the O rings. At 130k I am suprised at the pitting etc as this vehicle had had regular servicing and OAT coolant up until now.

Just some observations

JC

**Blknight.aus** · 25th July 2009, 07:45 PM

OOC did you use hot water and oil?

last one I did that had oil in the cooling system by piece flushing it the engine and its assosciated coolers came out nice and clean. The heater matrix however makes a very nice oil trap especially if its been plumbed in so that the flow is from top to bottom as opposed to bottom to top.

**justinc** · 25th July 2009, 07:54 PM

Used a product called G101, a non caustic biodegradable 'truck wash strength' type of cleaner, diluted to about 20:1. I started off with a hit of washing detergent thoroughly mixed in hot water, then ran and flushed. After that 3 more complete flushes and a run with the thermostat open with the G101. This was after replacing all the hoses and cleaning out the rad as best as I could. The heater was also purged before the hoses were reconnected and yes there was afair bit in there

So far so good, It's 'resting' in the workshop at present after a run to the east coast and back today,(About 200km) so I'll final flush again and add coolant Monday and see what eventuates. Fingers crossed.

JC

**Blknight.aus** · 25th July 2009, 08:12 PM

I actually ment when you tested the oil cooler...

I wont tell you about the time I forgot to do the leak test with hot oil on an oil cooling radiator on a piece of plant.... worked fine to 120% of system pressure when it was cold on the test bed. in winter it takes a long time for a bit of plant to heat up the oil enough to need cooling which then makes a big mess.

**justinc** · 25th July 2009, 08:21 PM

Originally Posted by Blknight.aus

I actually ment when you tested the oil cooler...

I wont tell you about the time I forgot to do the leak test with hot oil on an oil cooling radiator on a piece of plant.... worked fine to 120% of system pressure when it was cold on the test bed. in winter it takes a long time for a bit of plant to heat up the oil enough to need cooling which then makes a big mess.

D'oh! Sorry misunderstood.

No, I didn't use hot oil and I came to the conclusion that IF it turns out it WAS leaking then that would be why it didn't show up with air pressure under water.(although 100psi IS quite a bit

). I have measured these engines at 80Psi cold idle so there is a strong chance that they could leak when at operating temps, for sure.
I'll know for sure next week

Owner is quite prepared to replace the head if it comes to that, but first things first, it takes comparitively little time to check/ replace the cooler, and the system had to be cleaned anyhow.

JC

**Blknight.aus** · 25th July 2009, 09:05 PM

got a ricer mate who knows someone who knows how to custom make silicon hoses.....

might be going of to get me a new skill set.....

**DEFENDERZOOK** · 26th July 2009, 12:02 PM

if oil is leaking into the cooling system........

should you be able to get the coolant into the oil if you pressurise the cooling system........??

water is thinner than oil.......

it might be a good time to use a bit of chem-i-weld now that the cooling system is clean......

**DEFENDERZOOK** · 26th July 2009, 12:04 PM

forgot to ask......is it definitely engine oil in the cooling system......?

**Hendrik** · 20th March 2010, 08:49 AM

Well my oil cooler has failed. Had a bit of oil in my coolant after I did the head, but I thought that was from a bit of oil that leaked into the water galleries when the head was removed from the block. Walked into the garage this morning, to find oil absolutley everywhere. I haven't been able to have a proper look, will soon...could it just be the gasket failing? But I think I may be up for a new oil cooler. Just glad it didn't happen while it was being driven, i think an oil pressure gauge might be a good investment.

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