 | Home > Puma (Tdci) > Great mechanic needed in Boa Vista, all expenses paid!! |
 
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| RichieRich Member Since: 07 Jul 2013 Location: Cape Verde Posts: 36  
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Apologies for the subject heading....reads like spam! I posted a thread a while ago, non-starting 2007 Defender 110 and although I got excellent advice and help (thanks particularly to Ian at IRB developments) still got the massive dilemma of not being able to do the work personally. To cut a long story short I run a business on Boa Vista, Cape Verde and our Land Rover will not start. Boa Vista is below the Canaries off the West coast of Africa and lacks a lot of things on the island including competent mechanics familiar with Land Rovers. Not one has Ford IDS software to re-programme injectors that may or may not have been put back in the wrong way after cylinder head gasket change performed by the look of things a numptie mechanic on Boa Vista!! It's been round all the mechanics on the island (all 4 of them!!) and all are convinced the injectors are the problem.
I've been given all the advice on what I need to do so I won't go into the symptoms on the forum but if you are a great mechanic and fancy an all expenses paid trip to Boa Vista to fix my Landie then please can you get in touch to discuss it further? I'm looking to fly someone over from the UK, put them up with my girlfriend and I and our two cats and two dogs (so no allergies please) and provide food and drink all week. We run a tour company so we'll take you out on all our island tours showing you everything Boa Vista has got to offer (we do 6 different tours a week) so it won't just be all work work work but obviously the ultimate aim is to get Bubba up and running again as soon as possible. If you are interested please email me at rich.d.scott@gmail.com then I'll give you all the history etc of the Land Rover and send you a couple of links to Boa Vista so you can prepare yourself for what the island has to offer!! I don't want to sound rude but please only get in touch if you know Land Rover Defenders inside out. If you've been an expedition mechanic previously that would be amazing as the working conditions you will have to work on our Defender is going to be similar. It's non starting parked in the drive outside the house. Ill give you more info when you email and you'll understand!! Thanks for reading and fingers crossed someone out there can help me out!! Cheers, Richard |
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19th Aug 2013 8:18pm |
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| farmer giles Member Since: 09 Feb 2011 Location: worcestershire Posts: 1299 
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why didn't i train as a land rover mechanic
what a fantastic offer. if any one here takes up Richard's offer then PLEASE post some pictures up 
good luck, richard; i hope you get bubba sorted soon |
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20th Aug 2013 8:46am |
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| Norm4n Member Since: 31 Aug 2012 Location: Surrey Posts: 329 
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I think you should post some pictures up of Boa Vista now, that may tempt someone over there!
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20th Aug 2013 12:22pm |
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| Porny Site Sponsor Member Since: 31 Aug 2009 Location: Sutton Coldfield - West Midlands Posts: 806 
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Farmer Giles - as requested!
After chatting to Richard via email details were swapped, and flights booked... and D day approached. So 2 weeks ago now - off I go to Birmingham Airport - Suitcases in hand packed with spare parts and tools - and hand luggage full of laptop and diagnostic equipment. And a few pairs of shorts and T Shirts. First shock of the day was the excessive baggage charge... even after slimming my tools down I didn't quite expect to be 25kg over (and that was on top of the extra baggage allowance that was pre booked  ).
Just under 6 hours later and I was on Boa Vista. I left Birmingham with temperature of 8 degree's - so a nice surprise to get off the plane to over 30 degrees! Whilst I'm used to my nice workshop... working outside on the drive isn't that bad when it so warm! The downside was the 49 mosquito bites in the first 4 days - obviously like Brummie Blood!  Click image to enlarge So what did I find… if you think some English mechanics are bad, this is a whole new level… Injectors: This was the first shock! On checking the numbers on the injectors fitted and then interrogating the ECU it was obvious that the injectors fitted were not the ones programmed to the ECU. So, somewhere along the line the injectors have been swapped from original. For information – the engine will not run with the wrong injector codes. But this was nothing to what was found next… On removing the injectors it was obvious that at some point they had been stripped down (bearing in mind that there are very few places in the UK that can rebuild Puma injectors properly – so this was not a good sign). By the looks of it a set of molegrips, a hammer and a chisel were chosen tools! Click image to enlarge Not good! None of the injectors were fitted with copper sealing washers, so no chance of sealing. Luckily, I had a spare set of injectors with me. After seeing this – alarm bells were ringing to see what else they had done wrong. So, front end stripped down to check timing. Click image to enlarge Firstly, the timing was wrong – but more shocking was the state of the timing chain. The local mechanics had obviously played football with the chain, resulting in a combination of rust and sand – which with the oil had turned into a lovely paste that had grinded into the guides. Click image to enlarge So more new parts. All cleaned and timing locked up properly (with pin in the flywheel and pins in the cams) and then reassembled with new chain, guides and tensioner. Click image to enlarge Click image to enlarge Click image to enlarge The old front cover had been pryed off and bent (with a rusty spoon I think) – so a new front cover fitted, along with new crank seal. Normally these are glued on with RTV – but I prefer the aftermarket cork seal. New front cover fitted – using the correct alignment tool. Click image to enlarge Click image to enlarge Now the engine was timed correctly, next was checking all of the rockers (and cam lobe movement) to make sure none of them were bent or damaged. Click image to enlarge Once this was done, everything was reassembled. Replacement injectors fitted and programmed into the ECU. At the same time the ECU was also reprogrammed with the latest level software as this had never been done (this was to cause a problem later). It was at this point I also found that the chassis number in the ECU was not that of the vehicle!! Again, this causes issues!! – but more later. Due to damage to the conduit on wiring loom, the loom was stripped down, checked and re-taped up. The original problem was oil in the coolant – and a suspected head gasket. However, head gasket failure on a standard Tdci is quite rare (especially as the engine calibration will shut the engine down to save damage). And after looking at the old head gasket, no damage was visible. So, in my opinion head gasket failure wasn’t the original problem. The more likely cause was oil cooler failure. This is quite common on transits and other tdci applications (but not that common on Defenders). On stripping the oil cooler down, there was a huge amount of oily sludge inside… Click image to enlarge Click image to enlarge Again, in preparation I had an oil assembly with me (not actually available as a separate part from LR). This is actually an aftermarket part that is made better than the OE one. The problem was how to clean the oil filter assembly – however, an old school solution of an improvised parts washer (a cut down water bottle) and some petrol – which is randomly blue – sorted it out. The rest of the cooling system was then flushed (removing clumps of oily gunk) and refilled with coolant. Then just a case of putting it all together and bleeding the fuel system. Once all back together, fault codes cleared. Time to crank the engine. It was cranking over a bit slow, so battery was put on charge for an hour…. (I happened to take my C-tek charger with me lol) So, after a swim in the sea, time to crank the engine again. A short burst and then nothing. B*****er. Even shorting out the starter motor still didn’t result in anything. So starter motor off and stripped down (on the kitchen table). The bushes were knackered – in fact I have never seen a set so bad. No wonder it was turning over slowly. The starter motor was absolutely full of carbon and general c**p. Hrmm… where to get a new set of bushes… or a new starter motor. No chance of popping to a LR dealer on Boa Vista!!! After a search, nowhere had any bushes that were similar. Not looking good. However, a visit to the local garage and they assured us they could fix it… they had some larger bushes that could be filed down and soldered in place. So, we went back later… and surprise surprise, not done. By this point, I understood exactly why Rich had so much issues the local mechanics! The next morning, Rich went off to collect it… a few hours later and the garage had it ready tested on the bench. Time for the refit. A turn of the key the engine turned over. And then nothing. B*****r. The local mechanics strike again. I had never thought about taking a starter motor, but after a few calls – we managed to get a new one brought over via a friend. But this was a day away… but we had a few other jobs to do whilst we waited. The new starter arrived and fitted, and at last we could crank the engine properly – without a massive current draw (due to the old worn out starter). So fault codes cleaned, and the engine cranked. But still no start. Time for checking live data. Firstly, a new crank sensor was fitted, followed by a new cam sensor and now we had proper engine RPM displayed… Next, fuel rail pressure was checked (unless the ECU sees a minimum of 280 bar it will not start) – fuel rail pressure was quite happy. But still no start… and then the new starter motor started to make some horrendous noise. The new starter motor was faulty (admittedly a none genuine one). But for the time being, it would let me do some more tests. It was as this point – the ECU issue revealed its head. Whilst the engine would run with a wiff of solvent cleaner (we had lots of fun trying to find brake cleaner lol) so mechanically it was sound, there was still no fuel being injected. So an entry condition not being met. The cause… an Immo and IPK communication error. As mentioned earlier, integrating the ECU – the chassis number in the ECU was not the one of the vehicle. So the UK supplying LR specialist has been naughty! In short, to make it run they had turned off the immobiliser function in the ECU and messed with a few other things. I should have twigged this earlier – as there was other evidence of ECU tampering. But other faults had masked this problem. Unfortunately, when I had updated the calibration to the latest level I had reinstated the immobiliser. Basically I had put everything back the way it should be – not expecting the supplying LR specialist bodges – I hadn’t took any of the kit needed to correct this, so game over. At least this meant I had a couple of days to see some of the beautiful island that Jen and Rich live on… up until this point I was working every day on the LR. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge If you ever get the chance to visit Boa Vista – and tour the island I would!!! Obviously I would use Jen and Rich for this!! http://gigglinggeckoadventures.com/ Due to a mess up with my return flight, it gave us a couple of days to source another starter motor and thus on the day I was due home I was up at 6.30am fitting the new starter motor. So, I had to leave (annoying) with a vehicle now mechanically correct. With a faulty ECU. Tools and ECU packed – off to the airport. Checked in and just going through passport control my name got called out over the PA system, and once I let one of the guards know my name I got escorted off by someone from the airport closely followed by an armed police officer lol. Off we go to a private room… I had to open and unpack one of my suitcases so that the police officer could search through 'everything'... the thing he was most confused at was the circuit tester. They asked a few questions, and all was good. I was worried the rubber gloves were coming out! Anyway, back home to 14 degrees and rain... and back to normal work. And time to sort the ECU. Ian Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated  IRB
The home of the first modified Keswick Green 90 - and the first 2.4 Puma through both the 200bhp and 550Nm barriers. www.IRBdevelopments.com www.facebook.com/irbdevelopments www.integrated316.com www.facebook.com/integrated316 |
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24th Oct 2013 12:19pm |
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| x-isle Member Since: 26 May 2011 Location: Midlands Posts: 1327  
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Can't say anymore than that. Oh, apart from, I'm always looking at different places to visit, this is certainly different! It's now on the list. The "Dog Blog" is brilliant on their site! Craig Rogers
2007 Puma 110 XS 2011 Evoque Coupe Dynamic Lux www.craigrogers.photography |
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24th Oct 2013 12:30pm |
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| Porny Site Sponsor Member Since: 31 Aug 2009 Location: Sutton Coldfield - West Midlands Posts: 806
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Sonny is a great little dog.
Apart from the lack of a proper hospital, Boa Vista would be a great place to take a mountain bike as well! I know I would happily take mine out there.
I really enjoyed my time there.... and the local beer is good (but the imported Super Bock is even better). Ian IRB The home of the first modified Keswick Green 90 - and the first 2.4 Puma through both the 200bhp and 550Nm barriers. www.IRBdevelopments.com www.facebook.com/irbdevelopments www.integrated316.com www.facebook.com/integrated316 |
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24th Oct 2013 12:56pm |
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| x-isle Member Since: 26 May 2011 Location: Midlands Posts: 1327
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Every cloud and that.
They'll now certainly have more visitors to their website and maybe even more visitors to Boa Vista. I'm already looking at options for next year and now I know that SB is available, I'm there already!  Craig Rogers
2007 Puma 110 XS 2011 Evoque Coupe Dynamic Lux www.craigrogers.photography |
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24th Oct 2013 1:00pm |
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| Netforce Member Since: 14 Mar 2013 Location: Oostzaan Posts: 13  
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Wow, amazing adventure.
And I guess you were really happy that the rubber gloves didn't come out 
Regards, Net |
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24th Oct 2013 1:22pm |
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| Go Beyond Member Since: 30 Jan 2012 Location: Headcorn, Kent Posts: 6678
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Excellent write up Ian
Will you go back out there or can you just send the ECU ? |
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24th Oct 2013 1:25pm |
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| adafish Member Since: 30 Mar 2009 Location: atherstone Posts: 1381 
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that's what happened to the wing protector, was looking for that.. Putting Dreams on Drives at JLR Solihull..
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24th Oct 2013 1:43pm |
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| lrmaniac Member Since: 04 Feb 2010 Location: Lisboa Posts: 762  
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Ah! Nothing beats a nice, ice cold Portuguese beer!  Regards
Joao '10 Land Rover Defender 110 CC '08 BMW F800GS '64 SIIA Forward Control '69 SIIA 109 ZA CKD _____________________________________________ You have the right to remain silent. Anything you say will be misquoted, then used against you. |
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24th Oct 2013 3:09pm |
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| T1G UP Member Since: 08 Dec 2009 Location: Bath Posts: 3101  
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well done Ian
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25th Oct 2013 3:42am |
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| Porny Site Sponsor Member Since: 31 Aug 2009 Location: Sutton Coldfield - West Midlands Posts: 806
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Just slightly... the police officer had big hands!!!
Initially I am just sending out the ECU... But I do need to go back to set it up correctly. It needs pump learn and pilot injector learn doing. I also have a request from an ambassador on the neighbouring island who has broken L322 RR - which needs plugging into, so might do both in one go. Ian IRB The home of the first modified Keswick Green 90 - and the first 2.4 Puma through both the 200bhp and 550Nm barriers. www.IRBdevelopments.com www.facebook.com/irbdevelopments www.integrated316.com www.facebook.com/integrated316 |
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25th Oct 2013 6:46am |
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| wyvern Member Since: 13 Dec 2009 Location: Cornwall Posts: 2098 
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..... IRB International !
(warm and sunny places only..) Poppy - TDCI (Puma) 110XS 2.2 - Camper conversion - see the build here - https://www.defender2.net/forum/topic56530.html
Elgar -TDCI(Puma) 110XS Dormobile - now sold Devon & Cornwall 4x4 Response - DC126 |
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25th Oct 2013 7:30am |
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