Hi all.
I searched around but can’t seem to get a grip of this issue. Ive previously changed the head gasket, had the head skimmed and tested and all was well.
Recently ive had oil in the rad and header tank, tried flushing it with no luck. Now iv had an overheated and fount bubbles in the header tank with lots of hungry oil, its like a thick soup! Im sure the heads gone again.
So Ive stripped the rad and its blocked also full of oily gunge.
Pulled the thermostat which was reasonably clean but wouldnt open in hot water from a kettle but did finally after being boiled for a few mins in a pan, its marked at 86 deg, so not great.
Rad cap doesnt seem to open up at all but was allowing the bubbles to get into the header tank?
The block has been flushed and looks clean.

Ive ordered, from millers, head kit, bolts, rad cap, thermostat etc.

However Im not sure how this has happened, if the oil blocking the raf has caused the issue where has the oil got into the system. Or has the or Thad the head gone causing the oil leading to the overheat.

Just want to make sure Ive got the issues sorted before putting it all back together so it doesnt happen again, its been a couple of years since I last did the head and low mileage done.

Thanks in advance.
Lee.

where u based mate?

just make sure the block is flat when u take the old head off

Based in Manchester. The truck is running spot on apart from this, smooth and no power loss. I’ve heard theres a possibility of there being an oil crossover from the oil filter housing but not seen anything more on it.

fitler housing nah, possible the turbo though

Hmm wondered about that. There’s a little up and down play in the turbo shaft but no front to back. And I have been seeing some oil on top of the inlet manifold that I can’t trace so maybe the turbo seals? The rad was chock full of oil and gunge. I’ve no experience with turbos at all.

Turbo seals have nowt to do with yer coolant, only way oil can get into the coolant from your turbo is if the cartridge is cracked internally. Possibly dodgy stat caused your overheat which goosed your head gasket or head ,filling your coolant system with oil. Is your water pump working ok? Or it could possibly be the original gasket replacement wasn't 100%

Top and bottom hose were both getting hot so I’d say I had circulation. Before the overheat I noticed oil in the header tank and was flushing it believing it to be residue from last head gasket failure. Then it overheated and I found bubbles in the tank, once I cooled it down and got it running again the bottom hose wasn’t getting hot any more which I thought was the blocked stat.
I’m thinking the oil in the water has been the cause as after flushing the rad for hours it’s now running clear but it was solid with gunk.
After previous head gasket repair I had now bubbles or anything in the header tank, and it was torqued down in stages 30,60,90,120 nm and was still tight.
I’m guessing the bollock I dropped was not realising the severity of the oil and it not being residue, I’m just thinking if I redo the head is the original problem still present.

Couple of things - When you have had oil in the waterways, its a bugger to get rid off so will take ages or loads of cleaning. toque down settings seem good , always a good move to check each bolt in order at least twice before moving onto the next stage , and after the last stage ( ensures its flat , as by the time you get to the last one the first one could be just a smidgeon loose ).

It is possible you have two seperate issues , residual oil from the original change, and possibly a faulty rad cap, through degradation because of the oil

I’m not so sure it’s residual oil now I’ve drained and flushed the rad as there was so much of it. Heads coming back off and I’ll strip and check it for warps or cracks. New stat and rad cap will be fitted. Just trying to make sure the oil couldn’t come from somewhere else.

I have the same vintage truck and also the exact same issue. Been living with it for two years and keep the rad topped up so when you start and the water expands it dumps the oil in the header tank. Of course I have to empty that every so often. I'm leaving this job for warmer weather.
I suspect in my case its a warped head/block as I'm also leaking oil from the top end somewhere. Only recently acquired a decent power washer so will give the engine a good clean and find where the leak is. Strangely it does not consume too much oil so not desperate to fix.
Will be eagerly following this thread so please keep us posted, maybe with photos, as I cant believe this is an isolated issue.

I’ve got the head ready to lift as soon as it stops raining so I can post some pics of the inspection. Last time the head was pressure tested and skimmed as it passed but you could clearly see where the metal sealing ring had let go. I’m hoping to see something obvious again when I lift it.

Oil only mixes a few places with a k74, head, block or turbo . The turbo is the least likely culprit to be honest, ive never known one leak oil into the water yet. Block is not so common.,more than likely a hairline crack in the head , been down this line myself, replaced gasket and eventually put a new head on it (.waited for the truck to overheat before I finally replaced the head as it was running absolutely fine, it got to a stage of it was oil cooled I think, but the heaters were still red hot lol )

Had a look at the turbo, there’s movement in the shaft slightly up and down but nothing back and forth. There’s a a little bit of black oil pooled I. The horizontal inlet/ outlet but no more that half a teaspoon and there’s residue around the vertical outlet/inlet. There’s nothing pouring out of the intercooler but I have found oil on top of the inlet manifold below where the intercooler connects, but I’ve no experience with turbos at all.

That all sounds normal to me, there is always a small amount of oil I've found

The oil in the turbo , is more than likely coming from the crank case breather pipe, feeding into your turbo intake, quite normal as Kieron said. The throttle body seem to let it out onto the manifold too. It's worth fitting an oil catch can which eliminates this, keeps oil and shite out of your turbo, intake, intercooler etc.

I’ve got the head off, it still needs proper cleaning but straiyoff it looks to have been passing on the rear manifold corner and running down the block it also looks bloody suspect across several water ways. The bored and pistons look good but there’s something strange in no 4. It’s got what I can only describe as tiny bits of white polystyrene fluffy bits, it’s some kind of deposit. It’s on the piston face and valve area. I’m trying to upload pics, so far I can’t see any visible crack. I’m beginning to think Daviemtc nailed it with a bad install, my bad but no idea how I made a balls of it.

Ps how do I add the photos? I can’t find the add file option.

white polystyrene fluffy bits? lime scale? phaps?

crack could be inside the head

Quote: Ganers wrote in post #17

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Ps how do I add the photos? I can’t find the add file option.

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That looks like something has reacted with something else. I don't suppose you know if its ever had a head gasket sealer type product in it?

Not since I’ve had it, about six years and I head the head gasket last time.

I'm not convinced the white flakes are from the head but more possibly fallen off something else that is corroding i.e. an aluminium pipe. What is of concern is the right hand photo as you look on the forum and that shows rather bad erosion around what I think is the injection port or the glow plug port. The erosion seems to be half way through the gas seal ring part of the gasket. Obviously this is nothing to do with the water/oil mix but is a potential issue. I would gently clean the head surface, Block surface and the gasket to look for tell-tale signs ingress from one gallery to an adjacent.

Stupid question but Is this the original 4D56 block? looks like you have extra waterways on the manifold side that i don't have on the block I've got here or on the milners short motor. looks like the gasket is blocking them too.

According to the numbers it’s a 4d56, it’s an 05 plate warrior. I’ve got the head on the bench I’ll clean it all up including the gasket at report back. How reliable are the pressure tests on heads?