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Defderico

Member Since: 11 Dec 2020
Location: New Caledonia
Posts: 21

Puma 2.4 air in the fuel system

Hi there,

I bought a 110 HCPU with a 2.4 engine

I changed the fuel filter head
I have fixed the fuel line going to the fuel filter (see pic attached)
I filled up the fuel filter
I used a manual pump to bleed the system
Fuel arrives but then air appears. I looked at the fuel filter and notices that he is half-empty

I didn't notice fuel leaks from rear to the front

Could this be cause by a faulty fuel tank sender unit ?

Many thanks for your help and advice

Click image to enlarge

21st Sep 2025 11:30pm

HardCharger

Member Since: 03 Mar 2013
Location: Manila
Posts: 807

2011 Defender 110 Puma 2.4 SW Stornoway Grey

I see that you're using a blue box filter, check that it seats properly and doesn't wobble. Had one that did that, also blue box, changed it out and things went well right away. Stay away from blue box unless it's the actual OEM part (G Suffix) for what you need.

If the filter is one that actually works, and no other connections are loose, then yes, you may have to check / replace the sender.

I used to have an issue where if the fuel level dropped below 3/4 tank that the truck would stall and not start as it was fuel starved. Weird. Checked every thing, could not find anything. Resigned to just keep the fuel topped of and carried a jerry can with diesel to top off in cases of longer distance travel. It occurred to me that the only thing I didn't check was the sender in the tank. Got around to ordering a new sender as the tank was already being pulled down. Good thing too as I found that the installed sender at some point, had the cup thing removed and replaced with a weighted plastic bag!

The bag deteriorated, dropped the weights and floated to the top bringing the pick up tube with it so it would obviously ingest fuel when full then when there was already air space in the tank, ingest air with the fuel until more air that fuel was going through as the pick up tube was floating above the fuel line. So installed the new sender after fishing out the weights and flushing the tank. Works as should after.

Apologies for the long story but I figured it may help. No Better Friend, No Worse Enemy

22nd Sep 2025 1:54am

Defderico

Member Since: 11 Dec 2020
Location: New Caledonia
Posts: 21

I found what was wrong
The return pipe into the sender was broken and air was sucked prior into the fuel filter
As no sender was available in my country I modified it with a little pipe I inserted along the entire length
I securited the installation with 2 clamps

6th Oct 2025 3:53am

Defderico

Member Since: 11 Dec 2020
Location: New Caledonia
Posts: 21

Click image to enlarge

6th Oct 2025 3:56am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8454

2011 Defender 110 Puma 2.4 USW Stornoway Grey

Good find and find, well done. Cheers

James
110 2010 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

6th Oct 2025 8:31pm

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