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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 1326

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

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 Big Cry ). 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 Whistle

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


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Injector seats (photos taken by my glamorous assistant)


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Injector seats after cleaning


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 > 110 XS Double Cab
> Instagram @simonlanemind


Last edited by hank on 17th Sep 2020 11:09am. Edited 1 time in total

Post #856441 17th Sep 2020 9:02am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 12241

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

When you use the cutter to clean the seat, how to you prevent crud from falling into the cylinder?

I know it's usual to fit a plug in the hole to prevent this when cleaning the seat with a nylon brush and when cleaning the 'tube', but the plug would presumably interfere with the cutter.

Post #856462 17th Sep 2020 10:42am
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 1326

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

The cutter has a stem 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
> Instagram @simonlanemind

Post #856467 17th Sep 2020 10:54am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 12241

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Thank you, so obvious once you know! Embarassed

Post #856485 17th Sep 2020 11:58am
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 1326

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Thumbs Up > 110 XS Double Cab
> Instagram @simonlanemind

Post #856494 17th Sep 2020 1:10pm
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ozzie1989



Member Since: 25 Feb 2009
Location: Wales
Posts: 264

Wales 2010 Defender 110 Puma 2.4 USW Bonatti Grey

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 Thumbs Up Now: 2010 2.4 TDCi 110 Utility Wagon
Then: 2004 2.5 TD5 90 Hard Top (X-Tech Edition)

Post #856619 18th Sep 2020 6:54am
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 1326

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

I got it on ebay. 3m will do both sides Thumbs Up

https://www.ebay.co.uk/itm/324138668389 > 110 XS Double Cab
> Instagram @simonlanemind

Post #856631 18th Sep 2020 8:49am
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ozzie1989



Member Since: 25 Feb 2009
Location: Wales
Posts: 264

Wales 2010 Defender 110 Puma 2.4 USW Bonatti Grey

Thank you! Thumbs Up Very Happy Now: 2010 2.4 TDCi 110 Utility Wagon
Then: 2004 2.5 TD5 90 Hard Top (X-Tech Edition)

Post #856772 18th Sep 2020 11:59pm
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lord-haggis



Member Since: 12 Feb 2020
Location: Edinburgh
Posts: 70

United Kingdom 

hank wrote:


Side tube seal fitted

Click image to enlarge




Do you know if thats sold separately? My car has the sliders but they never bothered to fit the tube and I can only find the OE foam one when i've looked.

Post #861906 16th Oct 2020 12:39pm
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 1326

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Yeah I got mine from ebay. 3m will do both sides :Thumbs Up:

https://www.ebay.co.uk/itm/324138668389 > 110 XS Double Cab
> Instagram @simonlanemind

Post #861911 16th Oct 2020 1:14pm
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lord-haggis



Member Since: 12 Feb 2020
Location: Edinburgh
Posts: 70

United Kingdom 

Cheers Hank

Post #861914 16th Oct 2020 1:42pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 12241

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey


Click image to enlarge


Classic Landrover panel alignment in that photo, mine is just the same! Rolling with laughter

Post #861928 16th Oct 2020 3:05pm
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Supacat



Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 8623

United Kingdom 2013 Defender 110 Puma 2.2 XS DCPU Keswick Green

If every panel is out it sort of has it's own equilibrium.

Post #861944 16th Oct 2020 4:18pm
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 1326

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Yeah, doors could do with some adjustment on the hinges! > 110 XS Double Cab
> Instagram @simonlanemind

Post #862255 18th Oct 2020 1:32pm
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 1326

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

hank wrote:
The crankcase pressure seems to have reduced so will keep an eye on how much oil the Provent catches over time.


Bit of a follow up on this... Since sorting the injector seals once and for all the crankcase breather is passing no oil and as a result the provent is empty! Result Thumbs Up > 110 XS Double Cab
> Instagram @simonlanemind

Post #862443 19th Oct 2020 2:19pm
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