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Hi there, I'm new here..

We have a 2002 Boxer 2.0 HDI, with a problem...

The expansion tank has filled up with sludgy oil, where there should be water/coolant!

We have tried changing the head gasket and refitting the head after getting it checked / skimmed and flushing the coolant system through, but the expansion tank has rapidly filled up with the black sludge again.

Prior to this the van never overheated (I guess because there's oil where there should be coolant :( ), and there's no sign that there's water in the oil?

Can anyone give any advice as to what they think could cause the oil to sludge up the coolant so badly?

Many thanks!
 

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Oil in tank

Hello - on the HDI engine there is coolant cooling the oil near the oil filter. Where the filter screws in, you should see two coolant pipes, this unit corrodes, and oil mixes with the water (not the other way round due to oild pressure at 50+psi, water pressure at 10ish psi). To test, take the filter off, then unscrew the big nut (27mm) to remove the unit, block one of the pipes and pressurise the unit with a air hose, stick the unit in a bucket of water, if you see bubbles, the the unit is u/s. Hope this helps.
 
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