Thought I'd give my findings on this one:
History: Oil cooler failed in 2007 replaced with 2nd hand original valeo part from 2005 van.
Flushed through cooling system many times and used forte bio degreaser to remove all traces of contamination.
All was well with the van until November 2013 when I noticed oil in the coolant again!
Suspected oil cooler failed again!
So, bypassed the cooler by joining the two connecting coolant pipes with 10mm fuel pipe and the original hose clips.
Placed a thick plastic bag (cable tied) over the cooler pipes and drove for 100 miles to test for leakage.
None found!!
Flushed through the whole cooling system again, removed every hose and the header tank and flushed and backflushed for a good hour. Plus used a product called
http://www.dae2008.co.uk/products.html . Radiator flush, No affiliation! This did wonders and removed all traces of oil from the system. There was a lot left after just a water flush!!
Reconnected the oil cooler prior to flushing. Refilled the cooling system with anti freeze/ de ionised water mix.
600 miles later and is still as clean as a whistle! So will mark as solved
For now.........
Cheers to all for your input.
Adam..2003..1.9D..LX..Silver Crew Cab Van.....
If at first you don't succeed, destroy all evidence that you tried.