TD5 - oil in coolant

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Hi - this is my first dabble on the forum so here goes:
I have a 2003 TD5 Defender 110 and have just spent the last year clocking up 32,000 miles driving around southern Africa. Besides other hiccups along the way I had a persistent but intermittent electrical fault that caused the temp gauge to flick to hot, or sometimes cold, and put the engine into limp for a second or two most of the time. On a few occasions this led to the engine actually overheating on long hot climbs. I think I may have cured this with a new engine temperature sensor fitted towards the end of the trip.
HOWEVER, in the last couple of weeks in Africa a new problem developed - oil in the header tank. From not using a drop in the previous 95,000 miles she was drinking oil which appears to have gone straight into the header tank - engine oil was uncontaminated and rest of coolant clear. I assumed a head gasket had gone and managed to nurse her back to Cape Town to be shipped home. On checking the web it seems the problem may be a cracked oil cooler (see below links) with the first link blaming African water!
Disco2 TD5 oil cooler - SA 4x4 Community Forum - The only forum for the offroad and 4x4 enthusiast
Oil in the expansion tank - LR4x4 - The Land Rover Forum
td5 oil cooler failure
She isn't due back in the UK until April but it would be nice to get an idea of what is actually wrong - head gasket or oil cooler (not sure which is the lesser of two evils!)
Thanks
 
Still getting my head around this forum thing - just spoken to someone (mechanic) who reckons it is more likely to be a cracked head which sounds like big bucks - he also reckons a common fault on TD5s?????????
 
Hi - this is my first dabble on the forum so here goes:
I have a 2003 TD5 Defender 110 and have just spent the last year clocking up 32,000 miles driving around southern Africa. Besides other hiccups along the way I had a persistent but intermittent electrical fault that caused the temp gauge to flick to hot, or sometimes cold, and put the engine into limp for a second or two most of the time. On a few occasions this led to the engine actually overheating on long hot climbs. I think I may have cured this with a new engine temperature sensor fitted towards the end of the trip.
HOWEVER, in the last couple of weeks in Africa a new problem developed - oil in the header tank. From not using a drop in the previous 95,000 miles she was drinking oil which appears to have gone straight into the header tank - engine oil was uncontaminated and rest of coolant clear. I assumed a head gasket had gone and managed to nurse her back to Cape Town to be shipped home. On checking the web it seems the problem may be a cracked oil cooler (see below links) with the first link blaming African water!
Disco2 TD5 oil cooler - SA 4x4 Community Forum - The only forum for the offroad and 4x4 enthusiast
Oil in the expansion tank - LR4x4 - The Land Rover Forum
td5 oil cooler failure
She isn't due back in the UK until April but it would be nice to get an idea of what is actually wrong - head gasket or oil cooler (not sure which is the lesser of two evils!)
Thanks

If it's headgasket I would expext small quantaties of oil in the header tank. If it's large quantaties of oil as your post suggests, my money is on the oil cooler.

A compression test should help confirm this.
 
Hi Malcolm
I worked with LR in Moz for a few years , still in Moz and have a few Defenders . I have seen this problem at least a dozen times with TD5's in Mozambique . The oil cooler corrodes and lets oil into the coolant system . I have seen a new genuine cooler last for six months and corrode through .There is even a locally produced cooler available here on the streets of Maputo that is really over engineered and strong that will last till the next ice age . One piece of advise if I may , give the coolant system a really good clean and change all the coolant hoses that seem soft and mushy. I have seen plenty of ripped coolant hoses a few months after the cooler has been replaced , due to engine oil damage .My honest opinion is that the water in Maputo is slightly saline . This coupled with general lack of technical knowledge on antifreese percentages and the benefit of using a factory premix solution I'm sure is the culprit .
 
Hi
Thanks for this useful information which seems to accord with some of the information I'm picking up on the internet. Loved Mozambique and came in from Malawi and had 3 weeks there before going into Swaziland (also did Zimbabwe besides many other countries) - we were in Maputo so should have picked up one of the roadside oil coolers! Judging by the large amount of oil getting into the header tank after not many miles there must be a large aperture somewhere between the oil system and coolant system and it sounds as if the oil cooler is favourite as the engine is otherwise running fine.
Cheers
Malcolm
 
Yep it's probably the cooler, mines gone currently, cant afford to have it fixed so for now ive got to flush and refil the coolant and top up the oil every week.
 
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