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lbdmp

Member Since: 01 Feb 2025
Location: Rouen
Posts: 19

2010 Defender 110 Puma 2.4 SW Nato Green

Puma 2.4 blue smoke

My Defender, a 2010 Puma 2.4 model with 42,000 miles, has been broken down for several months.

My problem started suddenly with the appearance of blue smoke from the exhaust.

On the advice of others, I decided to replace the injector seals and the rocker cover seals. Unpleasant surprise on dismantling, the exhaust camshaft came loose (as shown on the picture), and a rocker arm (cyl4) fell into the cylinder head causing quite a bit of damage.
https://www.defender2.net/gallery/albums/u...G_4582.jpg

I decided to dismantle the cylinder head to replace it, but on dismantling the cylinder wall (cyl3) showed a strange mark.

The decision was made to replace the engine with a second-hand one, so we put it back together, started it up, coded the injectors and learned how to inject.

A short test drive, 5 miles and the Defender starts smoking again.

I've tried again since then, and it smokes even when the engine is cold.
The problem persists despite having done :

2x turbocharger
Injector seals
Test injectors -> one had a low flow so I replaced all 4 with new ones (original)
Glow plugs + intake pipe cleaning
Compression test ok
Clean sensors, MAP & MAF (also smokes with flow meter disconnected)

No fault found on diagnosis. I'm completely lost, is the smoke coming from a problem on the new engine... or from a component that hasn't been replaced...?

Thank you in advance for your help

G&M

1st Feb 2025 9:29pm

jim4244

Member Since: 13 Apr 2014
Location: Bedfordshire
Posts: 853

2007 Defender 90 Puma 2.4 CSW Zermatt Silver

Blue smoke from an engine is usually a sign that the engine is burning oil. One fault that can cause this is worn piston rings. You say that you have already done a compression / leak down test on each cylinder?

When did the replacement engine come from and did you fit it yourself? If its a guaranteed unit fitted by a garage then I would be speaking to the company that rebuilt the engine.

Jim

2nd Feb 2025 3:31am

jbcollier

Member Since: 29 Apr 2024
Location: Edmonton AB
Posts: 167

2009 Defender 110 Puma 2.4 SW Alpine White

Mine blows blue when cold. Doesn't burn a drop of oil.

2nd Feb 2025 6:31am

andy63

Member Since: 30 Jun 2023
Location: north east
Posts: 634

Re: Puma 2.4 blue smoke

lbdmp wrote:
My Defender, a 2010 Puma 2.4 model with 42,000 miles, has been broken down for several months.

My problem started suddenly with the appearance of blue smoke from the exhaust.

On the advice of others, I decided to replace the injector seals and the rocker cover seals. Unpleasant surprise on dismantling, the exhaust camshaft came loose (as shown on the picture), and a rocker arm (cyl4) fell into the cylinder head causing quite a bit of damage.
https://www.defender2.net/gallery/albums/u...G_4582.jpg

I decided to dismantle the cylinder head to replace it, but on dismantling the cylinder wall (cyl3) showed a strange mark.

The decision was made to replace the engine with a second-hand one, so we put it back together, started it up, coded the injectors and learned how to inject.

A short test drive, 5 miles and the Defender starts smoking again.

I've tried again since then, and it smokes even when the engine is cold.
The problem persists despite having done :

2x turbocharger
Injector seals
Test injectors -> one had a low flow so I replaced all 4 with new ones (original)
Glow plugs + intake pipe cleaning
Compression test ok
Clean sensors, MAP & MAF (also smokes with flow meter disconnected)

No fault found on diagnosis. I'm completely lost, is the smoke coming from a problem on the new engine... or from a component that hasn't been replaced...?

Thank you in advance for your help

G&M

Do you have working egr on it...?
And is it mapped?

2nd Feb 2025 8:45am

lbdmp

Member Since: 01 Feb 2025
Location: Rouen
Posts: 19

jim4244 wrote:
Blue smoke from an engine is usually a sign that the engine is burning oil. One fault that can cause this is worn piston rings. You say that you have already done a compression / leak down test on each cylinder?

When did the replacement engine come from and did you fit it yourself? If its a guaranteed unit fitted by a garage then I would be speaking to the company that rebuilt the engine.

Jim

Thanks for your reply. It's a second-hand engine that I fitted myself. The engine has 33,000 miles on it.
Yes I did the compression test which was positive (377 psi {26 bar} per cylinder)

2nd Feb 2025 8:54am

lbdmp

Member Since: 01 Feb 2025
Location: Rouen
Posts: 19

Re: Puma 2.4 blue smoke

andy63 wrote:

Do you have working egr on it...?
And is it mapped?

It is not mapped.
The egr is activated, I've tried unplugging it to keep it closed but the result is the same.

2nd Feb 2025 9:06am

lbdmp

Member Since: 01 Feb 2025
Location: Rouen
Posts: 19

jbcollier wrote:
Mine blows blue when cold. Doesn't burn a drop of oil.

Strange. Ours also smokes a lot when hot and we don't dare drive for fear of causing major damage.

2nd Feb 2025 9:10am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17610

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

What year is the engine and why was it removed from its original vehicle?

2nd Feb 2025 9:22am

andy63

Member Since: 30 Jun 2023
Location: north east
Posts: 634

Re: Puma 2.4 blue smoke

lbdmp wrote:
andy63 wrote:

Do you have working egr on it...?
And is it mapped?

It is not mapped.
The egr is activated, I've tried unplugging it to keep it closed but the result is the same.

But it could be stuck open or partially, and that could give you a richer than normal charge and the smoke..
Just a thought..👍

2nd Feb 2025 9:22am

lbdmp

Member Since: 01 Feb 2025
Location: Rouen
Posts: 19

blackwolf wrote:
What year is the engine and why was it removed from its original vehicle?

The engine was manufactured in 2009. It comes from an accident vehicle.

2nd Feb 2025 9:30am

lbdmp

Member Since: 01 Feb 2025
Location: Rouen
Posts: 19

Re: Puma 2.4 blue smoke

andy63 wrote:
lbdmp wrote:
andy63 wrote:

Do you have working egr on it...?
And is it mapped?

It is not mapped.
The egr is activated, I've tried unplugging it to keep it closed but the result is the same.

But it could be stuck open or partially, and that could give you a richer than normal charge and the smoke..
Just a thought..👍

I think it's a good idea. Do you know if I can use a shutter plate to try it out?

2nd Feb 2025 9:32am

bear100

Member Since: 22 Mar 2010
Location: South Wales
Posts: 1956

2010 Defender 110 Puma 2.4 USW Santorini Black

mine has blown blue from cold for a number of years, i think is to do with the injector seats? 2023 Defender L663 V8
2016 Range Rover Autobiography 4.4 TDV8 (gone)
2010 110 XS Utility 2.4TDCI
2010 Range Rover Sport TDV8 (gone)
2007 Discovery HSE TDV6 (gone)
1993 110 csw 200 tdi (gone)
1994 90 HT 300 tdi (gone)
1994 discovery 300tdi (gone)
90 hybrid 3.5 v8 (gone)
Range rover bobtail 3.5 v8 (gone)

2nd Feb 2025 9:59am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17610

It is common, almost normal, for a cold 2.4 to produce blueish smoke on startup and this is generally not something to worry about. It shouldn't do it when warm or hot though.

I don't think a stuck-open EGR would cause blue smoke and it would produce DTCs.

A 2009 engine could conceivably suffer from the PCJ hysteresis problem which causes destructive wear to bores and pistons. Do you have any evidence to make you believe it was running clean before its accident? What happens if you remove the oil filler cap with the engine running?

I would suggest a compression test would be a sensible next step, and taking a look at the bores with an endoscope through the injector holes. Alternatively take the head off for an inspection.

2nd Feb 2025 10:51am

andy63

Member Since: 30 Jun 2023
Location: north east
Posts: 634

Hmmm well I'll be at odds with bw..
If your egr valve was allowing loss of air it could well produce smoke...but Id still be inclined to get a smoke test done just to make sure the inlet side is tight..
Yes I would expect codes if its severe enough..but at least the egr is common to both engines producing the same symptoms so seems like a good place to start given its one of the few items not mentioned in the previous comments..

I thought the op had already got compression test results that were good??

2nd Feb 2025 11:05am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17610

Yes, missed the bit about the compression test!

Is the inside of the inlet manifold oily? Is the intercooler full of oil from the old engine?

2nd Feb 2025 11:42am

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