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Home > Puma (Tdci) > The strip down begins, TDCI head-gasket??
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custom90



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Post #716096 4th Jul 2018 2:04pm
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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
Picked up the head this afternoon,
It’s had a 10 thou skim, and all looking nice,clean and shiny.

Putting it all back together tomorrow, so fingers crossed Thumbs Up 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #716464 6th Jul 2018 5:38pm
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Stacey007



Member Since: 25 Sep 2015
Location: Cheshire
Posts: 3754
United Kingdom 
Very Happy


Keep us updated, hope you sort it.
Post #716484 6th Jul 2018 7:33pm
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Andy80



Member Since: 31 May 2013
Location: Essex
Posts: 490
England 2008 Defender 110 Puma 2.4 HT Cairns Blue
ian series 1 wrote:
Daniel

Number 4 was the cylinder with an odd combustion pattern, if any water was entering the bores, I’m 99% this was the one?
The bore looks good, as does the top face of the block,
Obviously it’s only a visual check though.



I can only hope now, that what I’ve done will be enough to cure the problem? Rolling Eyes



Scott,

It’s just nuts, bolts and chains assembled in an specific order... Laughing Thumbs Up

I’ve already been looking at its replacement... Mr. Green



Hi Ian,

Just abit of thought, have looked at the full length of the liner on Cylinder 4? .....Well what's visible as I have had cracked liners on Gen sets (albeit alot bigger capacity)




Andy Thumbs Up Working towards Carry on camping!
Post #716493 6th Jul 2018 7:56pm
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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
Hi Andy

I’ve had a good look at the block and bores, I’ve even had my magnifying glass out! , like you say (as far as you can see)
As you well know, the only way to be 100% is to pressure test the block,
But I really don’t want to go down that road yet! Rolling Eyes

To be honest, if it was that?
I can get a short recon unit for £1100, which would be the way to go,
I wouldn’t mess about with mine.



The guys who did the head said they would be very supprised if the block was at fault,
They said the only issues they have with them, is if it’s crank related.

I think I’ve done all I can for now, I’m replacing the pump and thermostat just so I can say it’s been done,
I will also back flush the matrix, block, and rad.

Fingers crossed Thumbs Up


Just incase anyone needs any work done, I can thoroughly recommend these guys,
Their workmanship is spot on, and the workshop is on another level. Bow down Bow down

http://www.hthoward.co.uk/

Thumbs Up 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #716505 6th Jul 2018 8:38pm
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MK



Member Since: 28 Aug 2008
Location: Santiago
Posts: 2420
Chile 2007 Defender 110 Puma 2.4 SW Chawton White
Interesting thread.

Did you find out if these heads can be skimmed further than what you have done?

thanks Puma 110" SW

.............................................................
Earth first. Other planets later
Post #716526 6th Jul 2018 11:28pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17432
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
ian series 1 wrote:
...
Just incase anyone needs any work done, I can thoroughly recommend these guys,
Their workmanship is spot on, and the workshop is on another level. Bow down Bow down

http://www.hthoward.co.uk/


I notice on their website they say they only take work from trade customers, not private.
Post #716527 6th Jul 2018 11:34pm
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Likeomg



Member Since: 29 Jun 2012
Location: Lake District / Newcastle
Posts: 2641
2010 Defender 90 Puma 2.4 HT Stornoway Grey
Sounds exactly the same as when mine went a few months back...

unfortunately i had to go back to work so its only done the 300 miles or so back from alive to home... have some pics i can upload when i get a chance.
Post #716534 7th Jul 2018 5:21am
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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
Today I put the TDCI back together.....


Headgasket on, this is the 3 hole gasket, which is the thickest you can get.
The marker holes are above where the high pressure pump is.


Click image to enlarge

Nice clean skimmed head....


Click image to enlarge

Head on, full set of new bolts, all 18 are single use on the TDCI.



Click image to enlarge


Next, making sure every thing is clean, a squirt of oil here and there, and drop the cleaned cams in place,
Insert timing pins back in the location holes.



Click image to enlarge

Next, fit the rockers, using new bolts on the carrier frame.


Click image to enlarge

Time to fit the tensioner, cam sprockets, then the chain and guides,
Using the gold links to line up with the arrows on the sprockets, the fuel pump sprocket has a recessed mark to line up the chain.

The tension is held back off the chain until the pin is pulled out.



Click image to enlarge


Click image to enlarge


Click image to enlarge

Always leave the cam sprockets, and pump sprocket bolts loose, before pulling the tensioner pin,
This allows the sprockets to move back slightly to lose the slack.

If you don’t, this is what can cause the chains to jump a tooth.


Front cover on, oil seal in, and starting to look like an engine again. Very Happy


Click image to enlarge

The Puma carries Possibly the longest aux drive belt I’ve ever seen, other than on a Scania!


Click image to enlarge



Click image to enlarge


Click image to enlarge


Oil and filter change and all done, considering it’s been stood for a week with the fuel rail and lines off,
It started quite willingly, I let it sit for half an hour on tickover, while I kept an eye on the water.



Click image to enlarge


Click image to enlarge

A quick run around the block, pulled over to look under the bonnet and it seems ok, apart from the Censored front crank seal was weeping! Big Cry
So I returned home to have a propper look, it’s Odd for a genuine Ford one to weep? I took it back out, and it appears to be the timing chain cover?

Stupidly, if I do these at work I always get a genuine seal, and cover.
Guess who thought he would save himself a few quid and brought a genuine seal, and non genuine cover,

The pressing isn’t that clever around the seal, and it’s pulling it away to one side. Big Cry

I will take it off tomorrow, and get a genuine Ford cover on Monday.

Hopefully that should be it?? Thumbs Up


Regarding the skimming, I’m not sure how far you can go on the TDCI?
The chap who do it, did say 10 thou was quite deep, and they wouldn’t go much more than that. Wink 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.

Last edited by ian series 1 on 7th Jul 2018 8:41pm. Edited 1 time in total
Post #716620 7th Jul 2018 7:36pm
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keith



Member Since: 15 Aug 2012
Location: Edinburgh
Posts: 2214
Scotland 
Ian
Thanks for an awesome detailed strip down and rebuild Thumbs Up

Keith
Post #716627 7th Jul 2018 8:06pm
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Andy80



Member Since: 31 May 2013
Location: Essex
Posts: 490
England 2008 Defender 110 Puma 2.4 HT Cairns Blue
Good work Ian, so after a drive round the block .....Are you still thinking to sell?


Andy Thumbs Up Working towards Carry on camping!
Post #716629 7th Jul 2018 8:08pm
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Rosco



Member Since: 03 Dec 2010
Location: Burntwood
Posts: 1833
United Kingdom 2015 Defender 110 Puma 2.2 XS CSW Montalcino Red
Glad to see its back up and running. Hope it's cured the issue.

Cracking write up Thumbs Up 2007 - Stornoway Grey 90 XS SW - Gone
2002 - Black Discovery II - Gone
2014 - Montalcino Red 110 XS SW
Post #716631 7th Jul 2018 8:13pm
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williamthedog



Member Since: 29 Dec 2012
Location: south wales
Posts: 3441
2011 Defender 90 Puma 2.4 PU Tamar Blue
Good write up. Think I'll go back to a push bike now.... It's easier to work on. Seriously top notch rebuild Thumbs Up
Post #716633 7th Jul 2018 8:39pm
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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
Cheers guys, Thumbs Up

I don’t think anything like this has been covered on the forum?
So it’s always good to have some sort of record.

I could have gone into so much more detail, but the thread would have ended up like a Haynes manual! Laughing
Plus I just don’t have the time...Rolling Eyes

Andy, I’m really not sure what to do with it?
I had a mint low mileage TD5 Disco metropolis before this, the H/G went in that, I did it, and sold it.

I think this one might go the same way?
Not sure yet ?🤔 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #716634 7th Jul 2018 8:55pm
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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
Out at 6.30 this morning before it got too hot!

Stripped out front cover again.


Click image to enlarge


Found the culprit! Censored



Click image to enlarge


The cover had a slight dish on the lip to one side, which was pulling the seal to one side, not worth trying to straighten it,
Cheap crappy parts, never worth the hassle Big Cry

I will order new genuine Ford cover, and another seal tomorrow,
Plus the 3 crankshaft pulley bolts, as they are only supposed to be tightened 3 times.
Don’t want to be breaking one of them off in the crank!! Thud 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #716660 8th Jul 2018 7:07am
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