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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347   
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Recently I've been experiencing the occasional "P0234-00 (28 ) turbo overboost condition" error which puts the vehicle into what feels like normally aspirated / limp mode until the fault is cleared.
Research suggested this could be a sign that the variable geometry turbo vanes were gunked up and sticky and I figured this was likely due to manky crankcase fumes being recirculated into the turbo inlet. As a test I disconnected the crankcase pressure recirculation hose from the turbo inlet, venting it to atmosphere. I also sprayed a can of wynns turbo cleaner through the turbo for good measure. Sure enough 2000 miles later no further overboost errors. However, the crankcase fumes were pretty bad so I needed a permanent solution. (It would also be an MOT fail) On investigation, the rocker cover pressure relief valve diaphragm had gone hard and crusty so I replaced that with a nice new flexible one 
While I was there I also fitted a Provent 100 - I went for the 100 because it's compact which is advantageous given the limited space in the engine bay but also because the inlet and outlet are 19mm which is useful as they match the existing Defender breather fittings so no adapter fittings required. Today I fabricated a bracket to mount the Provent which picks up on the clutch pedal box cover screws and plumbed it courtesy of a Corsa 1.3 CDTI breather hose from rocker cover outlet to Provent and the original, trimmed, Defender hose from Provent back to turbo inlet. Pleased with how it turned out, looks kind of OEM and the fumes exhausted from the Provent are spotless whereas previously they were grey smokey/oily and rank. Anyway, a few photos... Cardboard template for the Provent bracket. Unfortunately I forgot to take a photo of the steel bracket which has welded nuts for mounting the Provent  Click image to enlarge Provent fitted and plumbed. Click image to enlarge Click image to enlarge > 110 XS Double Cab Last edited by hank on 25th Aug 2020 8:38pm. Edited 2 times in total |
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25th Aug 2020 8:05pm |
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| Zed Member Since: 07 Oct 2017 Location: In the woods Posts: 3357  
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Nicely done. You'll be surprised how much oil it catches. WARNING.
This post may contain sarcasm. |
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25th Aug 2020 8:17pm |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347
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Yeah? I've put a length of opaque pipe on the waste as a temporary measure but will fit a transparent hose and tap arrangement when I get one so I can monitor the waste oil level > 110 XS Double Cab
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26th Aug 2020 11:20am |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347
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Rocker cover subcover fitted
Why does this part have sealing o-ring but holes open to atmosphere below 
Click image to enlarge > 110 XS Double Cab |
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4th Sep 2020 1:30pm |
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| Zed Member Since: 07 Oct 2017 Location: In the woods Posts: 3357
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2 questions.
What is that for? and Where do you put your beer/tea/fixings? WARNING. This post may contain sarcasm. |
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4th Sep 2020 2:32pm |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347
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And the final piece of the provent puzzle... Waste drain and tap plumbed to behind the front offside radius arm mounting, retained by a hose clip in an existing hole
Click image to enlarge > 110 XS Double Cab |
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4th Sep 2020 2:38pm |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347
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Its primary purposes it to avoid comments like those below  Beer goes in my mouth and fixings typically into the drain
> 110 XS Double Cab |
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4th Sep 2020 2:40pm |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347
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Having run the Provent for a few weeks I was not happy with the quantity of oil the engine was putting out via the breather due to excess crankcase pressure so decided to revisit the injector seal washers (AGAIN
 ). I could hear injectors ticking, especially when I opened the oil filler so at least one injector was not sealing.
The only thing I had missed previously (because I didn't have the tool) was cleaning up the injector seats so I got myself a seat cutter (15mm flat for those wondering) and set to it. The injectors were heavily carbon'd up so there had clearly been blow by and inspecting each injector hole with a borescope I could see a fair bit of carbon buildup around the injector seat where the copper washer seals. I cleaned up the four seats with the cutter being careful to remove only the carbon and no aluminium head material. I also cleaned up the bores to avoids any bits getting knocked down onto the seat. Inspecting with the borescope you can see the seats ended up back to bare metal. Also cleaned out the rocker cover breather system whilst it was apart. Cleared all the gunk and carbon out of the internal breather passage and the diaphragm etc. Surprising how caked this was! Obviously cleaned the injectors right up too. Reassembled with new OE copper washers, new clamp bolts to 6Nm+180, new return seal o-rings and a new rocker cover gasket. The crankcase pressure seems to have reduced so will keep an eye on how much oil the Provent catches over time. The injector ticking noise has stopped so definite improvement and the vehicle feels as though it's driving better... But this could be psychological 
I will remove the injector cover after a few heat/cool cycles to check that the injector clamp bolts are still tight as I wonder whether heating/expansion and cooling/contraction of the components may leave these out of spec causing the washers not to seal. Don't know. Fingers crossed this time gets it! Some photos... State of the injectors Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Injector seats (photos taken by my glamorous assistant) Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Injector seats after cleaning Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge > 110 XS Double Cab Last edited by hank on 17th Sep 2020 12:09pm. Edited 1 time in total |
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17th Sep 2020 10:02am |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347
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The cutter has a pilot rod that goes down the hole both to plug it and maintain concentricity. The crud sticks in the teeth of the cutter and comes out with it. I also blew each hole out with an airline and a bung in place
Click image to enlarge > 110 XS Double Cab Last edited by hank on 21st May 2021 3:36pm. Edited 1 time in total |
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17th Sep 2020 11:54am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17850
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Thank you, so obvious once you know!
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17th Sep 2020 12:58pm |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347
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17th Sep 2020 2:10pm |
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| ozzie1989 Member Since: 25 Feb 2009 Location: Wales Posts: 282 
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Sorry to jump back a bit but where did you get your 'side tube seal' from?
Looks to really tidy up the bottom of the door and may help seal the bottom of my doors in the corners  Now: 2010 2.4 TDCi 110 Utility Wagon
Then: 2004 2.5 TD5 90 Hard Top (X-Tech Edition) |
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18th Sep 2020 7:54am |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2347
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I got it on ebay. 3m will do both sides
https://www.ebay.co.uk/itm/324138668389 > 110 XS Double Cab |
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18th Sep 2020 9:49am |
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| ozzie1989 Member Since: 25 Feb 2009 Location: Wales Posts: 282
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Thank you!
 Now: 2010 2.4 TDCi 110 Utility Wagon
Then: 2004 2.5 TD5 90 Hard Top (X-Tech Edition) |
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19th Sep 2020 12:59am |
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