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Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

2000 Defender 130 Td5 HCPU Nato Green No Canopy

2.2 TDCI sluggish after head gasket replacement

We took the time to get the proper head gasket, timing tools, and other necessary gaskets to do this job correctly.

We started with an overheat issue, we tested the coolant for co2, and it came back negative. We reloaded the stock map, and it still was over heating. We swapped the TC from 1.1 to 1.211, still problem at speed. We changed the thermostat, still. So I decided to do a head gasket swap.

Upon disassembly, we noticed the the timing wasn't spot on, but didn't pay too much attention to it at the time. We removed everything and found no fault in the original head gasket.

We installed the new head gasket with new bolts. As they are stretch to yield.

We blocked off both sides of the EGR cooler and installed the non DPF exhaust.

We attached all the accessories and primed the engine with new motor oil.

We then filled with coolant and started the engine to go through the initial heat cycle.

No leaks were found.

We did two full heat cycles, and cool downs and no faults were found. took the vehicle for a short test drive, and the engine light turned on. We reset the code and the one that always comes on is the turbo boost performance. We checked all the hoses and they are tight. We checked the bolts on the intake manifold and they are all tight. We checked everything we could and the engine performance is sluggish at best. Mash the throttle in neutral and it eventually gets to 2000rpm and then slowly creeps to 3000rpm. There is a slight puff of white smoke.

Level ground, its very slow, and no pep at all. Once load is put on the vehicle like a slight uphill the engine light comes on and its the same turbo boost performance code.

What did we miss?

My nanocom is unable to do a pilot correction nor write the codes for the inj...I am told its suppose to be a 16 character code, but all I find on the top of the inj are 11 or 13 or 6 digits.

Stealership is not an option, its something silly i am missing... Can't leave well enough alone

20th Sep 2021 12:02pm

Ianh

Member Since: 17 Sep 2018
Location: Essex
Posts: 1982

I thought you had to do an ECU remap if deleting an egr and DPF on a 2.2 puma. So this may well be your issue.

https://bellautoservices.co.uk/store/puma-...-road-use/

Worth giving them a call re this as they can do remote maps as well.

20th Sep 2021 12:19pm

Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

That was already done by Alive for the customer...

That is why we completely blocked off the egr cooler and removed the dpf canister. Can't leave well enough alone

20th Sep 2021 12:24pm

Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

Tomorrow I am goin to remove the turbo inlet and pressurize the system to 10psi and soap up all the air lines and intake to find the air leak through bubbles...

I used the old Inj seals, it couldn't be those could it? Can't leave well enough alone

20th Sep 2021 1:22pm

Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

Found a hose clamp that was loose.

We pressurized the system to 1bar and listened for leaks. one was found before the intercooler. We are now buttoning up the ride for a trial

Was something simple, but the engine bay is so cramped its a chore to look around. Can't leave well enough alone

21st Sep 2021 7:44am

hank

Member Since: 12 Sep 2016
Location: South Wales
Posts: 2292

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

That's a great idea. What is the internal diameter of the boost hoses? Wouldn't mind doing this myself > 110 XS Double Cab

21st Sep 2021 8:24am

Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

We removed the turbo inlet hose and attached an old inner tube there with the quick disconnect fitting and held it in place with a hose clamp.

Its not rocket science, but it helps to keep it simple.

Latest results are in, we still have an issue, we will try the same technique but this time turn the ign on but leave the engine off.

I feel it could be an EGR leak.

I am out of options, and covid has a lot of my friends shops closed. Can't leave well enough alone

21st Sep 2021 9:35am

Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

hank wrote:
That's a great idea. What is the internal diameter of the boost hoses? Wouldn't mind doing this myself

56mm of or 52mm id on the turbo inlet.

All the boost hoses are 51mm id. Can't leave well enough alone

21st Sep 2021 12:30pm

Naf

Member Since: 07 Dec 2016
Location: Sandbox
Posts: 412

P2263-21 Turbocharger/Supercharger Boost System Performance- Signal amplitude < minimum

Possible Causes: Intake system blocked/leaking Manifold absolute pressure and temperature sensor fault Variable geometry turbine vane actuator fault Turbocharger failure

Action: Check the intake system for blockages/leaks, check for manifold absolute pressure and temperature sensor related DTCs and perform the relevant corrective actions Check the variable geometry turbine vane actuator linkage. Check the turbocharger bearing and oil seal. Install a new turbocharger as necessary.

Cut and pasted the above from B.A.S. website.

We checked for leaks this time with the ign switch on, no leaks were found.

I highly doubt its a turbo issue. Its in great condition and the actuator linkage moves freely. Can't leave well enough alone

21st Sep 2021 1:00pm

hank

Member Since: 12 Sep 2016
Location: South Wales
Posts: 2292

I'm sure I read the actuator wiring can wear through. Have you checked here? > 110 XS Double Cab

21st Sep 2021 1:27pm

Ianh

Member Since: 17 Sep 2018
Location: Essex
Posts: 1982

Naf wrote:
P2263-21 Turbocharger/Supercharger Boost System Performance- Signal amplitude < minimum

Possible Causes: Intake system blocked/leaking Manifold absolute pressure and temperature sensor fault Variable geometry turbine vane actuator fault Turbocharger failure

Action: Check the intake system for blockages/leaks, check for manifold absolute pressure and temperature sensor related DTCs and perform the relevant corrective actions Check the variable geometry turbine vane actuator linkage. Check the turbocharger bearing and oil seal. Install a new turbocharger as necessary.

Cut and pasted the above from B.A.S. website.

We checked for leaks this time with the ign switch on, no leaks were found.

I highly doubt its a turbo issue. Its in great condition and the actuator linkage moves freely.

People often forget about the Air Charge Sensor” part number LR032216 on a 2.2 puma as I’m sure the 2.4 does not have one

That’s what LR call it but in reality I think it’s an Air Charge Temperature Sensor.

Listed as part 8 on this diagram https://www.lrworkshop.com/diagrams/land-r...es_2.2tdci

Perhaps checking that’s connected, clean and working is worth while

21st Sep 2021 7:14pm

Gloucesternige

Member Since: 17 Jan 2020
Location: In the garage
Posts: 114

2011 Defender 90 Puma 2.4 HT Keswick Green

Just a "stupid" suggestion.

I don't suppose you or someone else stuffed a rag in an opening in the inlet system and it has been left in there?

Just thinking out the box?? Nige

Check out my You Tube channel
https://www.youtube.com/c/Defender90KeswickNigelsLandRoverchannel

22nd Sep 2021 11:48am

Co1

Member Since: 19 Aug 2018
Location: North Yorkshire
Posts: 3671

Have seen that done more than once Nige, so not a stupid question!

22nd Sep 2021 5:47pm

dgardel

Member Since: 30 Nov 2008
Location: Veneto (Heart & Head)
Posts: 3586

hank wrote:
I'm sure I read the actuator wiring can wear through. Have you checked here?

I was thinking the same thing.......... Discovery 5 td6 HSE Stornoway Gray Outback Engineering Limited Edition

IID Pro MV License

23rd Sep 2021 1:23pm

hank

Member Since: 12 Sep 2016
Location: South Wales
Posts: 2292

P2263-21 Turbocharger/Supercharger Boost System Performance- Signal amplitude < minimum

Possible Causes:
Intake system blocked/leaking
Manifold absolute pressure and temperature sensor fault
Variable geometry turbine vane actuator fault
Turbocharger failure

Action:
Check the intake system for blockages/leaks,
check for manifold absolute pressure and temperature sensor related DTCs and perform the relevant corrective actions
Check the variable geometry turbine vane actuator linkage.
Check the turbocharger bearing and oil seal. Install a new turbocharger as necessary.

Cut and pasted the above from B.A.S. website. > 110 XS Double Cab

23rd Sep 2021 2:00pm

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