Puma 2.4 oil blowby?

[carpdvl]

G'day

I've noticed a decent amount of oil in my catch can and leaking from the exit intercooler hose (intake manifold side) of late.

So checked this am by taking the oil cap off at running temp while running. Lo and behold it's ticking and spitting oil out the cap (and plenty of vapour).

What are the thoughts on cause? Injector seat? Or more sinister piston rings?

Can get a video if it would help diagnose?

Thanks
Gus

[carpdvl]

More digging online, and to pre-emptively answer my own question (such that anyone in the future may have a similar issue and stumble on this), very much seems like an injector seating issue.

Not sure if allowed here, cross-posting to another forum :o but the below thread pretty much exactly describes it.

DEFENDER2.NET - View topic - Excess Chuff? (Possible high engine crank case pressure) (https://www.defender2.net/forum/post857581.html)

And before video (from thread - near enough to exactly same as mine):

DEFENDER2.NET - View topic - Excess Chuff? (Possible high engine crank case pressure) (https://www.defender2.net/forum/post857581.html)

And after cleaning/seating injectors:

Chuff Update - YouTube (https://www.youtube.com/watch?v=RiBMOg_a6mQ)

Good thing stuck in lockdown!

[DiscoMick]

Might be worth checking for a crack in the exhaust manifold or a leak caused by a loose bolt.

[carpdvl]

Might be worth checking for a crack in the exhaust manifold or a leak caused by a loose bolt.Thanks Mick - for my learning how would a crack / leak in the exhaust manifold lead to oil / exhaust spitting out the oil filler?

Or do you mean just the oil spitting out of the hoses?

[scarry]

Catch can could be culprit,bypass it and see how you go.

Engine oil not over full?

If problem still persists,compression test is probably the next thing to do,or take it to your local indie,and see what they say.

[carpdvl]

Catch can could be culprit,bypass it and see how you go.

Engine oil not over full?

If problem still persists,compression test is probably the next thing to do,or take it to your local indie,and see what they say.

Thanks for your input Scarry. Hadn't considered the possibility the issue could be the catch can! I'll have to check... Gut feel is its okay as it is filling (too) well still so if it was blocked up and restricting the rocker case pressure it probably wouldnt be getting much oil into it.

Oils good - measured it last change (5k km ago) and dipstick is about half / two thirds up the hatched part.

I'm thinking its these injector seats but if not that will be the way I go! The two inner injector seals in the rocker case have had quite a bit of oil seepage / plenty of gunk built up, especially second to front, so expecting it'll be that one/combo of that and the other. Plan to pull the injectors and have a peek down the barrel this weekend. I'll report back with pics for future ref

[DiscoMick]

Thanks Mick - for my learning how would a crack / leak in the exhaust manifold lead to oil / exhaust spitting out the oil filler?

Or do you mean just the oil spitting out of the hoses?The exhaust manifold on ours cracked and had to be replaced. Was letting dirty oily air out. I was told Ford redesigned it with ribs to make it stronger. But that's only a guess in your case. Good luck with it.

[DazzaTD5]

As already mentioned, the injector seals allowing blow by is reasonably common.\
When doing the injector seals replace the big rubber looking seals for the plastic cam cover otherwise they will continue to leak mess to the outside.

[carpdvl]

As already mentioned, the injector seals allowing blow by is reasonably common.\
When doing the injector seals replace the big rubber looking seals for the plastic cam cover otherwise they will continue to leak mess to the outside.Cheers - have the parts en route now including the rocker cover seal, little rubber seals for the injector breathers, copper washers and new stretch bolts.

Out of interest does anyone have any tips for keeping debris from falling into the cylinders when cleaning? I bought an injector seat cutter and at the moment seems to me best bet may be to just dip that in heavy grease to catch the carbon crud it cuts?

[carpdvl]

As a follow up for anyone who stumbles on this in the future.

Fixed this yesterday - links to videos of the before and after

Relatively easy job just takes a bit of time to keep everything clean. Some good videos on YouTube how to do it on ford transits (same donk).

You can see in the pictures below how dirty the second injector was (and the seal above) as compared with the first which was fine. Third also had evidence of the same happening but not as bad (not pictured).

Involved pulling the injectors and cleaning them with carby cleaner and replacing the washers on them. Also used an eBay special injector cutter seat to clean the seats up to bare metal from carbon. Just used some normal high temp grease on the cutter to catch the gunk as it cut it. Can see a seat after cleaning in photos.

Before vid:

Puma Defender 2.4 injector seat - before fix - YouTube (https://youtu.be/oT3zWbL7rVA)

After vid - note lack of exhaust and cyclical piston hissing of the exhaust escaping around the injector:

Puma Defender 2.4 injector seat - after fix - YouTube (https://youtu.be/SBPZjyObeUE)



https://uploads.tapatalk-cdn.com/20210822/f85cbf3fc736d221ca87ac457ef4586c.jpghttps://uploads.tapatalk-cdn.com/20210822/fe46123f4ba9f0629f34c9938bed27cc.jpghttps://uploads.tapatalk-cdn.com/20210822/013256f0037ca8d91f5efc0948a3aa92.jpghttps://uploads.tapatalk-cdn.com/20210822/71b4f071576cbd2d0b7b04110fa05e25.jpghttps://uploads.tapatalk-cdn.com/20210822/a10093fc17998f0f8aefc844c833dbc2.jpg

[skidrov]

Nice work.

Can I ask which size cutter you used (perhaps also a photo or link)? I have seen various bits of contradictory advice as to which to use.

[carpdvl]

Was a 15mm x 19mm flat cutter. I bought the kit at the below. If you're in Sydney welcome to use mine to save yourself some coin.

Note that 15mm is the cutting edge - anything bigger than the 19mm won't fit down the injector bore (not sure if there is even any cutter that comes in 15mm x larger than 19mm

17pcs Diesel Injector Seat Cutter Cleaner CDI Carbon Remover Tool Kit | eBay (https://www.ebay.com.au/itm/291914607479)