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Jensen

Member Since: 05 Jan 2013
Location: Poitou Charentes-France
Posts: 20

Defender 2.4 Puma TDCI New engine fitted and guess what?

Hi

After searching high and low for a 2.4 TDCI engine after ours died lasyt year with over 300K Km's we eventualy bit the bullet and bought a brand new one which was sent out to France with 4 new injectors etc.

Timed new engine up with the injection pump off the old engine using varios corresponding tutorials off the internet, programmed new injectors useing nanocom evo . Swapped all the auxillaries over useing new gaskets, water pump etc , filled with oil, coolant, turned engine over first on the starter with the crank sensor disconected to prime with oil and she fired up first time . Let her get up to temperature on tick over and all was good, no leaks, everthing spot on !

But : There is a tapping ! Can only be heard above tick over and when the engine is warm ? Starts and runs absolutely spot on, no smoke, no engine fault codes but as soon as she gets up to temperature there is a rev related tapping ?

Engine supplier thinks that the timing is out and its the pistons hitting open valves ?

Knowing that the timing was the most important point of this operation I took a lot of time to maticuously set it by the book ! Engine supplier since suplied procedure and corresponds with exactly how it was done .

( 2 x cam cogs locked with 6mm drills, flywheel locked with special tool through crank shaft sensor holder, 3 black links on chain lined up with arrows on cam cogs and hole in injection pump cog etc )

We have listened with a stepthoscope over every inch of the engine, scratched heads, checked , re-checked, injectors bolts etc to no avail .

Absolutely unbelievable ! Just can't believe it !

if anybody could shed any light it would be much appreciated.

Thanks in advance

1st Mar 2024 4:53pm

landy andy

Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 6060

2006 Defender 110 Td5 USW Zermatt Silver

It doesn’t help you, but I doubt engine would start, and run so well if incorrectly timed. I think your problem must be something else.

A new VCV would always be my starting point on these engines.

1st Mar 2024 9:53pm

Jensen

Member Since: 05 Jan 2013
Location: Poitou Charentes-France
Posts: 20

Thanks for your reply !
Totally agree with you ! Best of my knowledge you
Can’t check the timing now it’s all sealed and back together .
The VCV was relatively new on old engine/pump . Never did
a relearn because you can’t with nanocom ? But it was fine all
the same .

1st Mar 2024 11:26pm

Jensen

Member Since: 05 Jan 2013
Location: Poitou Charentes-France
Posts: 20

Surely if the timing was so far out that the pistons were hitting the valves there would be starting problems, smoke and diesel knock, fault codes ??

I want to be sure before I strip it down again to check timing !

2nd Mar 2024 3:24pm

Siwynne

Member Since: 04 Nov 2016
Location: West lancs
Posts: 628

It won’t bend a valve is mistimed just break a cam follower bolt or the ladder assembly. Would run like a bag of crap too

2nd Mar 2024 3:55pm

Jensen

Member Since: 05 Jan 2013
Location: Poitou Charentes-France
Posts: 20

Yeh ! That’s what I thought .

If it was hitting the valves you would think you could hear
It through the followers etc But you can’t ?

2nd Mar 2024 4:57pm

NickMc

Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1681

Injectors in tight? Blowing out past them?

2nd Mar 2024 8:42pm

Jensen

Member Since: 05 Jan 2013
Location: Poitou Charentes-France
Posts: 20

Yes ! Injectors are tight ! 6nm + 180 *

Checked them twice ! Probably don’t like that 2 bolt system

2nd Mar 2024 10:05pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2512

2007 Defender 110 Puma 2.4 SW Chawton White

Was the CKP holder already in place in the new engine? To my knowledge this setup is done before the cylinder head is installed. I may be wrong...

As well, make sure the injectors are original Denso and not counterfit. It can be very difficult to spot the difference. Puma 110" SW

.............................................................
Earth first. Other planets later

3rd Mar 2024 1:15pm

Jensen

Member Since: 05 Jan 2013
Location: Poitou Charentes-France
Posts: 20

Hi

Yes the crank sensor holder was already on and bolted up.

The engine came from a very reputable UK engine refurbisher who also supplied the Denso injecteurs

3rd Mar 2024 1:25pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2512

I would try using the older injectors. Puma 110" SW

.............................................................
Earth first. Other planets later

3rd Mar 2024 1:46pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2512

Is it so audible to upload an audio? Puma 110" SW

.............................................................
Earth first. Other planets later

3rd Mar 2024 5:32pm

SJM2018

Member Since: 06 Jul 2018
Location: Bristol
Posts: 296

2011 Defender 90 Puma 2.4 XS CSW Aintree Green

My 2.4 had been making a ticking sound, that I couldn't find the source of.

I had the clutch replaced when I switched to the Ahscroft output shaft and it resolved the ticking.

So could it be coming from the clutch? 2011 CSW XS 90

4th Mar 2024 9:11am

Jensen

Member Since: 05 Jan 2013
Location: Poitou Charentes-France
Posts: 20

MK wrote:
Is it so audible to upload an audio?

I don’t know ? Will have to put a vid up on YouTube and link to it ?

4th Mar 2024 8:01pm

Jensen

Member Since: 05 Jan 2013
Location: Poitou Charentes-France
Posts: 20

MK wrote:
Is it so audible to upload an audio?

Thanks for that but I changed the clutch etc last year when I changed the gearbox/transfer input
Shaft for the Loff one !
It was making a noise before or after !

4th Mar 2024 8:07pm

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