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Discussion Starter #1
Hi I have a 2004 1.9d non turbo, the engine was running a bit lumpy and smoking until really warmed up so I decided to change the injector nozzles and fit new timing belt kit as I didn't know when it was last done, as the engine had 150000 it would need its second one. This sorted it out or so I thought! today I started the van and it started to mis and puff smoke out again, the coolant level light was on so I topped that up and started the engine after a couple of minutes the header tank had oil pouring out of it, rang somebody who knows a bit and he said bypass the oil cooler and check if oil comes out of the pipes, well it didn't just filled the header tank up again. Could head gasket failure cause such a problem or will it be more serious like a cracked head. I don't have the gear to do a compression test, anyone else experienced this and sorted the problem?
 

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Oil and water mixing is generally a petrol issue on diesels its usually caused by the oil cooler describe how you bypassed it

cracked head/head gasket will cause pressure in the water not oil mixing again diesels and petrols sufer different symptoms
 

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Discussion Starter #3 (Edited)
the way I bypassed it was just to take the water pipes off the cooler and join them together, I thought i might see oil coming out of the cooler but nothing, the header tank filled up quickly with quiet a thick layer of oil on top of the water, so I guess it must be something serious? It had been running very lumpy/missing when cold and chugging white ish smoke which got better as it warmed up
 

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Ok thats the correct method to bypass but as i say head/gasket issues dont usually cause oil mixing on these sounds like you might be better with a replacement engine !
 
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