This is an excellent video that tells you where are the weep holes. I will inspect the two on the side and run a wire to see if there is oil around the oil cooler. If there is oil than that proofs oil cooler needs to be replaced along with the seals. I replaced the seals 6 months ago, I think it’s either the rear main seal or the oil cooler again.

https://youtu.be/ZgjxbNbH-pA

Oil filter housing can leak on these engines

Correct, I replaced the oil filter housing seals https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F192362694307

Interesting about the swirl flap motor. Just reassembling this today and for the life of me I couldn't attach the clip into the arm on the underside. Ended up taking the LH manifold out and attaching the clip and motor and then bolting it to the manifold to stop it flapping about. With a bit of faffing and an hour later I managed to put it all back into position with the connecting aluminium joining bush square in each part of the manifolds.

Real pain in the A to do. Hopefully never again !

Looked up the positions of the flaps as I was concerned how this all worked (never had to work with swirl flaps before)

From what I've read and seen videos of - the left hand manifold (as you look at it) the arm faces towards the front of the engine and the right hand manifold the arm points towards the back (so opposite directions).

Hopefully this is correct as I didn't see it in your instructions (unless I've missed a bit)

Great write up by the way. Really helpful with photos and corresponding torque settings. Saves other people (such as myself) hunting them down which can take ages.

Much appreciated

Hi there guys, sorry for resurrecting this thread but i have a issue with my OM642 i did the oil cooler installed everything forgot to tighten the turbo oil spilled out again took everything off cleaned it then reinstalled everything then tried to start again and the car didn't wanted to start it just cranks over and over and over prior to the oil leak (first reassembly it started on the 4th crank) now it will not start is it possible that since i broke off the brake booster hose (small tip off it car will not start?) I ordered one but it takes a week until it arrives or i'm missing something thank you.

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