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SJM2018

Member Since: 06 Jul 2018
Location: Bristol
Posts: 296

2011 Defender 90 Puma 2.4 XS CSW Aintree Green

Engine failure?

Hi all,

Yesterday I noticed a burning smell when out in the defender (2011 2.4 with BAS remap and EGR delete).

I drove for 30 minutes, parked for 15, and then I could smell burning on the journey home. The engine was up to temperature for the journey home, there wasn’t any smoke and no difference in power - so assumed the smell was coming from outside.

Today I started the defender (no problem starting); but it was running really rough (engine shaking) with lots of white smoke that smelt strongly of burning.

So I stopped it, checked for fault codes (none), cleaned the map + maf.

When I restarted, the rough idle had gone, but it was still smoking and smelling of burning.

I then took it round the block and the white smoke stopped, but the exhaust gas still smells strongly of a nasty burning smell.

Oil level is stable and no evidence of coolant in it.

Coolant is a little lower, but then the engine is still warm so will double check.

What else could it be? Split pipes? It doesn’t sound like a VCV failure?

Stu 2011 CSW XS 90

3rd Jan 2024 3:54pm

SJM2018

Member Since: 06 Jul 2018
Location: Bristol
Posts: 296

Further checks:

Coolant level normal once cool and no bubbles in it when engine running;
In torch light, smoke seems more blueish;
When engine oil filler removed, seems to be a lot of pressure (but no smoke); and
Inlet manifold from EGR up, is covered in oil. 2011 CSW XS 90

3rd Jan 2024 5:04pm

BrickBox

Member Since: 05 Oct 2021
Location: Wales
Posts: 838

2008 Defender 110 Puma 2.4 USW Zermatt Silver

Injector seals blowing I’d take a guess at. Causing extra pressure and forcing oil past a seal somewhere. 2008 2.4 110 Utility Station Wagon XS.

3rd Jan 2024 6:00pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20443

I’d change the VCV just in case as they aren’t expensive, are you sure there isn’t water in the fuel?
CHT sensor might be worth looking at too.
Both of these things don’t flag up a DTC, water in fuel or failed VCV because of it can cause all sorts of weird things to occur.
Glow plugs should put up a DTC if it was those, not sure about injectors but they should show the correct pressures with live diagnostics but we don’t all have access to that.
Check the air filter, and it’s pipework too.
With the weather so wet, you never know.

Wouldn’t the injector seals show signs of oil / fuel deposits around them if they were going?
I know I’ve heard they are very tricky to remove. No Guts, No Glory.
🇬🇧🏴󠁧󠁢󠁥󠁮󠁧󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁳󠁣󠁴󠁿🇮🇪🇺🇸⛽️🛢️⚙️🧰💪

3rd Jan 2024 6:44pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2420

2007 Defender 110 Puma 2.4 SW Chawton White

Vote for injector seals and coolant test. Puma 110" SW

.............................................................
Earth first. Other planets later

3rd Jan 2024 7:24pm

SJM2018

Member Since: 06 Jul 2018
Location: Bristol
Posts: 296

Thank you for the replies.

Tomorrow morning I’ll remove the engine cover and have a look to see if there is any oil around the injectors.

I’ll also remove the bonnet and have a proper look at the coolant.

Finally, I’ll check the water separator on the fuel filter.

There’s a commercial injector specialist just down the road from me; they do loads of vans / commercial vehicles. So they should have experience cleaning the injector seats and replacing the seals on the Ford engines.

I added some Millers treatment and stuck some shell fuel in it earlier; but that doesn’t seem to have made much of a difference. 2011 CSW XS 90

3rd Jan 2024 9:01pm

NickMc

Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1628

I would stop driving it in case it has a leaking injector or the likes.

3rd Jan 2024 11:14pm

SJM2018

Member Since: 06 Jul 2018
Location: Bristol
Posts: 296

So had a proper look at the coolant and it’s fine - although slightly low

Checked the water separator and there was a small amount of water in it - maybe 10 ml

Removed the engine cover and while the injectors felt solid, they were sitting in nasty oil.

Booked into a local injector specialist on Tuesday; they are going to remove and test the injectors, clean the seats and refit (if they’re ok).

Intending the replace the VCV, MAF and MAP too; they are all the original parts so 13 years old now.

Will also change the oil, oil filter, air filter and fuel filter.

Hopefully that does the trick and I don’t have an issue with the headgasket / piston rings.

Click image to enlarge

Click image to enlarge 2011 CSW XS 90

4th Jan 2024 10:39am

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2420

Not always possible, but I have the chance to stay looking at the screen while they check the injectors. Puma 110" SW

.............................................................
Earth first. Other planets later

4th Jan 2024 11:53am

hank

Member Since: 12 Sep 2016
Location: South Wales
Posts: 2301

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Those injector seals are gone so you're taking the right course of action.
Use genuine/high quality copper washers - the cheap ones are copper coated steel and don't compress/squish and subsequently don't achieve a seal.

If your injectors are found to be faulty my advice (learned the hard way) would be to buy brand new genuine Denso replacements. Stay away from reconditioned/remanufactured. Why do I say this you ask??

Click image to enlarge > 110 XS Double Cab

4th Jan 2024 12:45pm

NickMc

Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1628

Yes don’t waste you time with recon injectors on these! I buy them from Merlin Diesel Specialist.

I wouldn’t go swapping all the sensors, as you can cause yourself more problems, again buy genuine or quality, cheap sensors and aftermarket are a nightmare.

4th Jan 2024 4:08pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2420

Once I´ve got a "Hella" boxed MAF. It was a total joke. Puma 110" SW

.............................................................
Earth first. Other planets later

4th Jan 2024 4:11pm

NickMc

Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1628

Yes plenty of counterfeit parts out there especially on eBay,

4th Jan 2024 4:50pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2420

That time I could tell because of the terrible finish of the piece. However with the VCV is a lot more difficult or rather impossible. Puma 110" SW

.............................................................
Earth first. Other planets later

4th Jan 2024 4:53pm

SJM2018

Member Since: 06 Jul 2018
Location: Bristol
Posts: 296

Had an update from the garage:

Injectors tested ok, so they suggested sticking them back in;
Two glow plugs dead, so having the full set replaced; and
Compression test ok - cyclinder 4 was lower at 320 (others we 350-380), but they said it got there quick and held compression fine.

So hopefully cleaning the seats and replacing the injector seals, should do the job.

Kind regards
Stu 2011 CSW XS 90

10th Jan 2024 10:42am

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