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chrismack85



Member Since: 25 Feb 2020
Location: Birmingham
Posts: 65

United Kingdom 1999 Defender 90 Td5 PU Belize Green
2.4 2008 top end rattle diagnosis
Hi all…
Ok 2008 2.4 84k miles, ex utility so probably been running at idle in a field every day…

Tapping / rattle constant wi th knock… I’ve driven it for around 3 hours since collecting it and the noise does not change in anyway other than follow the revs
Video here

Note it’s note making the noise when there’s no compression (injector out)

https://youtube.com/shorts/1Vwz-SyqMxI?feature=share


So far done the following
- ran without the aux belt - noise still there
-Swapped the injectors and recoded and re-learn (by specialist/ software etc)
-New injector seals top and bottom
-VCV valve etc to rule out diesel knock / usual gremlin listed on forums
-Changed oil and filter and fuel filter - no metal
-Timing chain kit inc tensioner and gears, chain was stretched nearly half a link
-Checked timing locked in place for above
-Replaced entire rocker arm ladder compete kit as I found a rocker scored where it rests against the hydraulic tappet above cyl No1 all the others where smooth.
-compression test 380, 380, 390 and 370psi
-checked around cam shafts for cracks
-checked around exhaust manifold for witness marks of cracked manifold

I’ve lost the will to live… I’ve been driving it as needs must to and from garages etc and it’s not getting worse… pulls fine as if nothings wrong other than the rattle…

Few specialists suggest piston slap… anyone any experience of this? Does it get worse?

Annoyingly my borescope won’t go down the the injector or glow plug port.

I’ve been around it with a stethoscope/probe and it sounds like a metal on metal from the front end drivers side below/around the cam

TIA as I’m losing the will to live guys!
Cheers
Post #945804 14th Mar 2022 9:33pm
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Angus_Beef



Member Since: 30 Apr 2015
Location: Oslo
Posts: 434

Norway 2015 Defender 110 Puma 2.2 SW Corris Grey
um wow, thats a lot. Maybe try a nice and thick 20w-50 to see if there is an immediate change that could point toward something in the bottom end? Roaming around 🇳🇴🇨🇭
Post #945833 15th Mar 2022 9:57am
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 429

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey
Stuck hydraulic lifter? Meaning you're getting a bit of tappet noise?
Post #945847 15th Mar 2022 12:19pm
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chrismack85



Member Since: 25 Feb 2020
Location: Birmingham
Posts: 65

United Kingdom 1999 Defender 90 Td5 PU Belize Green
Replaced the whole rocker rail assembly complete with hyd lifters, rockers etc
Post #945873 15th Mar 2022 4:35pm
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5663

2006 Defender 110 Td5 USW Zermatt Silver
As you found one rocker scored, have you checked the condition of its replacement? Could that be the issue?
Post #945881 15th Mar 2022 6:26pm
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chrismack85



Member Since: 25 Feb 2020
Location: Birmingham
Posts: 65

United Kingdom 1999 Defender 90 Td5 PU Belize Green
Only ran for an hour so prob won’t have any witness marks on replacement
Post #945898 15th Mar 2022 8:43pm
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Fatboy Slim



Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

Wales 
I had one like this in the other day. It was a knackered injector. Had the four tested. One was totally stuffed, another borderline stuffed. Ended up putting four recon ones in it and was perfect after that. Might be worth testing them before going any further.
Post #945954 16th Mar 2022 2:37pm
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Fatboy Slim



Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

Wales 
Failing that could be a small end....
Post #945957 16th Mar 2022 2:46pm
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chrismack85



Member Since: 25 Feb 2020
Location: Birmingham
Posts: 65

United Kingdom 1999 Defender 90 Td5 PU Belize Green
Did it sound like in that video link?

We put another set of injectors In/ recoded and calibrated on LR software relearn etc and still coming from cyl no 1

3 garages LR/transit suggested based on everything I’ve don’t so far it’s prob piston slap or little end 🤷‍♂️

Also noticed yesturday running it without rocket cover that the first 3min run and the oil was only seeping out the top of the rocker rail oil ports

2nd and 3rd run the oil shot up like the fountain outside that famous vegas casino and hit the ceiling 6m up…

Last lastly the oil seemed to froth or solace out on the drivers side front corner even tho the engine is cranked up so wondering if that’s an indicator or something going on with a valve there above n01
Post #945958 16th Mar 2022 2:50pm
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Dave2068



Member Since: 06 Apr 2018
Location: Sutton Coldfield
Posts: 6

United Kingdom 2008 Defender 110 Puma 2.4 DCPU Keswick Green
Chris, had the same noise on my Puma for 3 years. Turned out to bit a crack in the camcarrier allowing the hydraulic tappet to vibrate. Found it when I was changing an injector.
Ended up changing Cam Carrier, Exhaust Cam etc etc >Had this done in Dec 2021
Post #946441 21st Mar 2022 9:38am
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chrismack85



Member Since: 25 Feb 2020
Location: Birmingham
Posts: 65

United Kingdom 1999 Defender 90 Td5 PU Belize Green
Where was the crack - could you see it if you took the rocker rail off… I’ve looked all around where the cam shafts go into the casting the sit in?

I’m just about to push the button on a new engine 🤮 so be great if it is that…
Was it obvious?
Cheers
Post #946450 21st Mar 2022 10:25am
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miles_thedefender



Member Since: 28 Apr 2022
Location: London
Posts: 3

United Kingdom 2009 Defender 110 Puma 2.4 USW Santorini Black
Hi Chris, did you ever find out what this issue was, it sounds like the same as i'm currently having - Ive just changed all four injectors and seals this morning with no luck after.
Post #1044007 27th Aug 2024 12:58pm
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