 | Home > Puma (Tdci) > The strip down begins, TDCI head-gasket?? |
 
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17432   
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I am shocked at the price of the EGR cooler!
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27th Jun 2018 1:35pm |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127 
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EGR cooler is ok, no leaks under pressure so that’s something.
Carry on with removing head now, I still could do with finding out how much of a skim they will take? My local Indy, and Ford dealer don’t know 
There is very little info to be found on the TDCI regarding things like this.. 
Just incase anyone needs this for future reference.... Head removal,  Click image to enlarge Head tightening, Click image to enlarge 80" 80" 86" 88" 90" Wanted, Forward Control Anything considered. |
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28th Jun 2018 11:39am |
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| hornet Member Since: 04 Jan 2010 Location: Western Europe Posts: 361 |
There exists OEM head gaskets for TD4 from 1.1 to 1.3 mm thickness (.5 mm steps). I do not know the genuine thickness, but you could measure. That would give you an idea for skimming...
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28th Jun 2018 2:29pm |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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Yes, once I get the head off I can measure the piston height and then look at gaskets,
I’m sure the head gasket fitted is a 3 hole? I’ve got a number for a local chap, who has done a few Transit heads, so that’s a good start 
Click image to enlarge 80" 80" 86" 88" 90" Wanted, Forward Control Anything considered. |
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28th Jun 2018 2:47pm |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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Aaarrrhhhhh!
Stuck again! Had to go back to work tonight and pick up a work van, my 86” which I’m using as a daily developed a misfire on the way home
I’ve not got time to mess about with it, it’s nothing serious so I parked it up for now. Anyway went to do a bit more on the Defender and came unstuck trying to remove the big A/C / alternator bracket that runs from the top end, to the bottom end. Removed all the bolts, but along with bolts they had decided to use 2x Allen head screw in studs at the top, Guess who didn’t have a 9mm Allen key socket on him?
It needs to come off before I can remove the front pulley plate that’s in-front of the timing chain cover! I think by the time the head comes off, I will end up with a bare block!!  80" 80" 86" 88" 90"
Wanted, Forward Control Anything considered. |
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28th Jun 2018 7:45pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17432
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It's a blooming nuisance, that bracket! I need to repair the threads in the head for the front branch of the exhaust manifold but that bracket has to come off for access. It's such a hassle that I've been putting it off for about 5 years.
Not having a/c I am tempted to cut the top off the bracket since the top does nothing. I am not sure if it contributes to the stiffness of the block. |
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28th Jun 2018 9:47pm |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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I don’t think modifying it would matter?
As It’s only fitted to the Defender, so I can’t see that it helps to strengthen anything, It’s just there as a fixing point. I know the one you mean, the single one right at the front! Why didn’t they machine or cast that bracket so it was easily accessible?
They must have breathed a sigh of relief when that engine finally fitted under that bonnet, I find it’s all a bit naff to be honest! I’m not really enjoying the work  80" 80" 86" 88" 90"
Wanted, Forward Control Anything considered. |
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29th Jun 2018 5:18am |
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| Ellisboy Member Since: 13 Oct 2013 Location: Deep South Posts: 539 
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Sounds like a nightmare of a job mate
Stephen. |
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29th Jun 2018 6:40am |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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Looking at a 2011 works Defender this morning, later cast alloy brackets appear to be just bolted on, and don’t use the recessed studs, obviously they were only used in the first few years of production? 80" 80" 86" 88" 90"
Wanted, Forward Control Anything considered. |
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29th Jun 2018 6:55am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17432
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I've not looked closely at a later one to see the difference (have only an '07 to refer to). The bracket has always seemed to me to have a disproportionate number of fasteners. It is interesting too that each bolt is numbered (cast into the bracket) and appears to be intended to be tightened sequentially, though for the life of me I can't see why it would matter on such a big, non-dimensionally-critical lump.
I really have always had the impression that adaptation to fit the TDCi and MT82 into the Defender was done reluctantly by LR at Ford's direction, and those who "engineered" it were really not interested. Every aspect of the installation shows signs of being done at absolute minimum cost, and has a strong smell of bodgery. Such a shame that this is how the evolution of the production Land-Rover ended (and I don't count the 70th as a production Land-Rover). |
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29th Jun 2018 7:35am |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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Mines 08 so would be the same as yours,
I did notice the numbers by the bolts, starting from 1 at the bottom, I can’t see the logic in why you would have to do this in sequence? I also wonder if it’s held on with hollow dowels somewhere? As much as I love my 90, like you it does make you realise how crap the Puma engined Defender actually is! (Sorry to those who think otherwise) It now makes me wish I had a TD5 under the bonnet! I am seriously thinking about selling it when I’ve done the work now. I should have really kept my nice Disco 2.... 80" 80" 86" 88" 90"
Wanted, Forward Control Anything considered. |
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29th Jun 2018 7:56am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17432
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Aha, I did keep my Disco 2 (and have been using it the last week or two since it has a/c and the Def doesn't)!
I don't remember any hollow dowels or anything other than the bolts to locate the bracket, but my memory may be playing tricks. I have a spare 2.4 Puma engine that I bought some years back, it had been replaced since apparently it was making lots of blue oil smoke when running, and the owner suspected the PCJ problem. I have not yet got around to investigation it in depth, but did find when I stripped off some of the ancillaries that the turbo has worn bearings and was full of oil, so I am cautiously optimistic that the bores may be fine, and that the smoke was caused by the failed turbo seals and not anything more significant. I did remove the ridiculous alternator/compressor bracket to get the manifold off, and I don't remember any locating dowels from when I did so. Another Puma feature that really irritates me is the tapped hole in the rear end of the exhaust manifold for the heat shield bracket. Anyone who thinks that it is good engineering to have a shallow, M8-threaded, blind hole in a cast exhaust manifold really should have chosen a different profession! The tragedy of the Puma Defender is that in many ways it is the best of the line, for example the MT82 gearbox is (in my opinion) far superior to anything LR fitted since synchro was provided on 1st & 2nd gears, the dash is good, the seats are by far the best. Even the engine has its good points - the torque curve makes it the most driveable (I have always been disappointed by the feebleness of a stock TD5 at lower revs although it's fantastic when the turbo kicks in). The disappointment comes from the throughly sloppy and unprofessional way that the whole thing was cobbled together, with a fragile fuel system, a really useless transmission adaptor, and the worst clutch for 100 years. Every aspect of the installation suggests to me that Ford did it because they had no choice and at absolutely minimal cost. |
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29th Jun 2018 9:50am |
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| defender9 Member Since: 12 Mar 2016 Location: Fylde Coast Posts: 1629 
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Looks like you have a heck of a job with the Puma Ian. Good of you to post your findings as it may help us other Puma owners in the future. Hope you find that it’s not too expensive a fix.
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29th Jun 2018 12:08pm |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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Hi John
I think this needs to be on the forum, There really is very little about headgasket/egr cooler/ coolant loss problems on the net. I’m not sure if that’s a good or a bad thing?
Hopefully this weekend I can have some answers as to what the cause was? And hopefully a head gasket will be answer? Sorry I missed you last weekend, it was all a bit hectic to say the least! 80" 80" 86" 88" 90"
Wanted, Forward Control Anything considered. |
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29th Jun 2018 12:36pm |
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