Checking back in on this thread after nearly a year. To recap, I went through everything* as part of a front cover reseal and didn't really find a smoking gun. It's consistently fine on cold starts in warm weather with 15w40 (oil light off w/in 5 secs) and consistently terrifying in "cold" weather (here in the PacNW, that's 35-45F, oil light on >10 secs, up to 30 sometimes). Warm oil pressure is w/in spec any time I've measured.
The oil flow up front is convoluted. Can anyone confirm whether the pressure sensor gets oil if the filter's being bypassed? The relief spring (there's only one in my 95--I assume handles pressure and bypass duties) measured in spec, but the only thing that makes sense to me is a hyperactive bypass valve because the engine sounds fine while the oil light's on. In fact, it's pretty consistent that the lifters are quiet *until* the oil light goes out, then they clatter a little.
I'm going to fill it with 5w40 next oil change just to test my theory. I'm betting it "solves" the problem. Kind of wishing I'd replaced that relief spring now, even though it was in spec...
* pressure sender + checked with gauge, pickup tube + o-ring, pump, relief spring, oil filter brands, etc.
Cheers,
joe b
pdx or
95 Disco v8 5-speed 199k