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zone30



Member Since: 07 Sep 2012
Location: Gent
Posts: 669

Belgium 2011 Defender 110 Puma 2.4 X-Tech LE Nara Bronze
EGR tip
This comes from my dealer, but first some history:

After owning the car for about a year (just under 3 years old then) the dreaded chucka chucka sound appeared.
As it was still under warranty, they replaced it, so no more noticeble sound: problem solved.

Now, about another year later, it is back so as I have an extended warranty, I went back expecting an other replacement.

Just talked to the head mechanic and what they did was drill a small hole into it, and put in some fluid grease on the gears inside and closed the hole back up. They also do this now with new to be installed replacement EGRs.

It should solve the issue, but they said to keep an eye on it because if it returns again it will be a replacement.

The reason they do this is because they have fitted several and they almost all came back with the same complaint within a few months.

I'm just mentioning it here so others can try this before spending the money on a replacement.
Post #407238 13th Mar 2015 12:59pm
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ericvv



Member Since: 02 Jun 2011
Location: Near the Jet d'Eau
Posts: 5816

Switzerland 2009 Defender 110 Puma 2.4 SVX Station Wagon Santorini Black
Post #407239 13th Mar 2015 1:07pm
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zone30



Member Since: 07 Sep 2012
Location: Gent
Posts: 669

Belgium 2011 Defender 110 Puma 2.4 X-Tech LE Nara Bronze
Yes, but it should be an almost unoticable sound. You'd have to concentrate to hear it. If it loud, it's dying...
Post #407241 13th Mar 2015 1:11pm
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ericvv



Member Since: 02 Jun 2011
Location: Near the Jet d'Eau
Posts: 5816

Switzerland 2009 Defender 110 Puma 2.4 SVX Station Wagon Santorini Black
My EGR failed almost from new within the first 5000 km with the truck frequently going into limp mode and engine light on, but that had nothing to do with excessive sound. It was replaced by a new one, and in the next two years it was a relatively loud screeching sound each time on turn off, which I thought was normal, and actually it probably was. Then when the truck was 2 years old, I switched from cheap French supermarket diesel to BP Ultimate diesel, and I never looked back. Within two tanks of that stuff the chuka chuka cycle became an extremely gentle, but still audible sound. And that until today, now at 6 1/2 years. Maybe worth a try for you too (unless you already doing that). Thumbs Up
Eric You never actually own a Defender. You merely look after it for the next generation.
http://youtu.be/yVRlSsJwD0o
https://youtu.be/vmPr3oTHndg
https://www.youtube.com/watch?v=_GtzTT9Pdl0
https://www.youtube.com/watch?v=ABqKPz28e6A
https://www.youtube.com/watch?v=rLZ49Jce_n0
https://www.youtube.com/watch?v=XvAsz_ilQYU
https://www.youtube.com/watch?v=K8tMHiX9lSw
https://m.youtube.com/watch?v=dxwjPuHIV7I
https://vimeo.com/201482507
https://www.youtube.com/watch?v=ZSixqL0iyHw
Post #407247 13th Mar 2015 1:30pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17307

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
zone30 wrote:
Yes, but it should be an almost unoticable sound. You'd have to concentrate to hear it. If it loud, it's dying...


I have said this several times in previous posts since I believe it to be the case, but usually have been shot down in flames by the "chukka chukka is normal" school! Big Cry

I believe that a correctly-functioning Puma EGR is almost silent in operation.
When it starts making the chukka-chukka sound it is deteriorating, although it may work for years in this state.
When it then stops making this noise, it has failed.
Post #407249 13th Mar 2015 1:35pm
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ericvv



Member Since: 02 Jun 2011
Location: Near the Jet d'Eau
Posts: 5816

Switzerland 2009 Defender 110 Puma 2.4 SVX Station Wagon Santorini Black
How do you define which of the two is more audible: "almost silent in operation" versus "an extremely gentle, but still audible sound"? Not so easy comparison without having the trucks side by side, but I think we both are saying more or less the same thing using different words. Thumbs Up
At least to compare light output in reliable numbers, we have the standardized measured, raw, effective, calculated lumen,.... or don't we? Looking for my hat now Whistle Laughing You never actually own a Defender. You merely look after it for the next generation.
http://youtu.be/yVRlSsJwD0o
https://youtu.be/vmPr3oTHndg
https://www.youtube.com/watch?v=_GtzTT9Pdl0
https://www.youtube.com/watch?v=ABqKPz28e6A
https://www.youtube.com/watch?v=rLZ49Jce_n0
https://www.youtube.com/watch?v=XvAsz_ilQYU
https://www.youtube.com/watch?v=K8tMHiX9lSw
https://m.youtube.com/watch?v=dxwjPuHIV7I
https://vimeo.com/201482507
https://www.youtube.com/watch?v=ZSixqL0iyHw
Post #407255 13th Mar 2015 1:43pm
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ian series 1



Member Since: 17 Nov 2014
Location: south
Posts: 3127

United Kingdom 2008 Defender 90 Puma 2.4 CSW Bonatti Grey
Just to confirm, my 2.4 goes chuka chuka chuka
I have also noticed all the transits we have in at work all make the same noise, Peugeots do depending on what engine is fitted.
I thought its normal behaviour? Never heard one make any other noise other than that?

When running a diagnostic test on them, they make the same noise, and it all shows up ok, and working on the screen. 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #407330 13th Mar 2015 5:39pm
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zone30



Member Since: 07 Sep 2012
Location: Gent
Posts: 669

Belgium 2011 Defender 110 Puma 2.4 X-Tech LE Nara Bronze
You'll notice! If you are driving and it is audible over the engine, it's too loud.
When you turn off the engine and you cannot but hear it, it's too loud.
If you turn off your engine without specifically listening for it and don't notice, it's ok, even if when you concentrate on it and then do hear it.

It's quite a noticable difference. I came home this evening and forgot to listen for it and can't remember hearing it, so it's fine again. Before I could nit ignore the sound even if I wanted to.

In fact, even it wasn't solved without any cost, I would've gotten it removed out of the ecu. Cost is the same as a replacement but it's a definate solution.
Post #407344 13th Mar 2015 6:50pm
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o4dn



Member Since: 08 Jan 2010
Location: South West
Posts: 538

France 2009 Defender 90 Puma 2.4 SW Alaska White
Re: EGR tip
zone30 wrote:
[...]
Just talked to the head mechanic and what they did was drill a small hole into it, and put in some fluid grease on the gears inside and closed the hole back up. They also do this now with new to be installed replacement EGRs
[...]


Maybe you should post some pics of what they did, where they drilled the hole, etc., that could help others who'd like to give this a try?
Post #407348 13th Mar 2015 6:58pm
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zone30



Member Since: 07 Sep 2012
Location: Gent
Posts: 669

Belgium 2011 Defender 110 Puma 2.4 X-Tech LE Nara Bronze
Was planning to. Will do it tomorrow!
Post #407369 13th Mar 2015 7:59pm
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pob1968



Member Since: 20 Apr 2014
Location: uk
Posts: 239

Only thing that worries me with this is how do they stop the metal swarf from going inside the EGR valve when drilling into it? 110 Hardtop
Post #407483 14th Mar 2015 12:04pm
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ickle



Member Since: 22 Jul 2010
Location: South Vendee
Posts: 1776

France 2008 Defender 110 Puma 2.4 CSW Alpine White
Is the front face plastic?
Post #407521 14th Mar 2015 3:41pm
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x-isle



Member Since: 26 May 2011
Location: Midlands
Posts: 1327

Wales 2007 Defender 110 Puma 2.4 XS CSW Santorini Black
{Damn phone, double post} Craig Rogers

2007 Puma 110 XS
2011 Evoque Coupe Dynamic Lux
www.craigrogers.photography


Last edited by x-isle on 18th Mar 2015 7:00am. Edited 1 time in total
Post #408594 18th Mar 2015 6:54am
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x-isle



Member Since: 26 May 2011
Location: Midlands
Posts: 1327

Wales 2007 Defender 110 Puma 2.4 XS CSW Santorini Black
I'd be more worried if I couldn't hear the self-clean when switching off the engine.

You shouldn't hear it when the engine is running and it shouldn't be too loud on the self-clean, that's the sound of it sticking.

However, it should certainly be noticeable when it self-cleans on shut down.

Anybody who suggests it should be almost silent is incorrect. Any Ford derivative with this EGR makes a noticeable noise from new. When I swapped my EGR out for a new one, it made the same noticeable noise.

I'm only saying this as a lot of people might read this thread and think they have an issue when they probably don't.

I'd love to know what grease they are putting in that will withstand the amount of heat that goes through the EGR. I would of thought it would just burn. Craig Rogers

2007 Puma 110 XS
2011 Evoque Coupe Dynamic Lux
www.craigrogers.photography
Post #408595 18th Mar 2015 6:57am
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o4dn



Member Since: 08 Jan 2010
Location: South West
Posts: 538

France 2009 Defender 90 Puma 2.4 SW Alaska White
Agreed, mine had *always* been audible from new when turning the engine off.

At some point in the past, I had unplugged the EGR and left it like that for a few thousands miles, but it clogged up, so that when I plugged it back again (for MOT or the like), it made an awful screeching sound that I could hear even when driving, mostly at gear change at low speed! That was not normal... even though the MIL never came up (and no error code was ever logged in the ECU, I checked with my Scanguage)

But I did not replace the EGR, instead, I poured some 2SO in every fill-up and a few more thousands miles later, it's back to normal, I cannot hear it while driving, but I can when switching the engine off.

And I reckon this is the normal behaviour for that EGR.
Post #408598 18th Mar 2015 7:56am
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