TRANSIT 2.4 TDCI 2004 135 BHP head swap top TDDI

[eddydar]

Hi,

Wondering if someone can help, I've recently changed the head on my transit 2.4 tdci 2004 model, tensioner went cracked cam carrier etc.

Replaced everything but got a head from a tddi, drilled a hole to accept camshaft sprocket & fixing screw, put it all back together and it misfire's slightly and wont rev past 2000 rpm. White smoke pouring out of exhaust. Are the TDDI and TDCI cams the same ?

I've did a compression test and all cylinders came back at approx 220 bar. The head came from a transit specialist in Lichfield who said came from an engine were the bottom end went and conrod came through the block.

I didn't realise but overfilled the oil it was about 10 mm over the max and ran if for 2-3 mins but have since drained it back to the correct level. But still smokes just wondering if the oil is in the combustion chamber or are the cams different.

Starts fine even had the injectors checked from a common rail specialist proper machine that checks about 5 parameters and they came back fine.

Battery light is on, could this be the alternator, was fine before.

No fault codes.

Help.

[angeleye]

think the only difference is the camshaft sprocket position sensor ,you have fitted this havnt you,and drilled fixing point in correct place,are you sure you have timing correct,why not just use your own camshafts,compression seems a bit low thought it should be nearly twice what you have reading, which could point to incorrect timing ,did you pin the flywheel as well as camshaft sprockets also which tentioner have you put on as this is your original problem ,you need tentioner 1138760 and the blade to go with it is 1112290,if you have put the tentioner with the tin plate spring on side of it its no good there the crap ones,correct head gasket should be fitted as well as there are 3 different thickness

[karl]

was this comprssion test done with engine running or not if not then 220 bar is enough

[angeleye]

Im not douting your wisdom or knowledge karl....im looking at psi..as thought thats what op meant as 220 bar is way way to high.sure these should be at around 400/450 psi.irc mk6 2.4 tddi checked cold with fuel discomnected should be 19 bar about 300 psi with a 60 psi 4 bar allowance....and think tdci is higher.l do stand to be corrected.

[bambi mk 1]

220 bar = 3190 psi approx.You would need some starter and battery to churn that over.There is a difference in the injector heights between tddi and tdci cyl heads .Measure down through the injector holes with a calipers.

[karl]

Im not douting your wisdom or knowledge karl....im looking at psi..as thought thats what op meant as 220 bar is way way to high.sure these should be at around 400/450 psi.irc mk6 2.4 tddi checked cold with fuel discomnected should be 19 bar about 300 psi with a 60 psi 4 bar allowance....and think tdci is higher.l do stand to be corrected.

psi not bar as mine is a psi also in the hand book you should realy have the engine at operating temp before conducting a compression test but if not possiable you have to go of what you have

[karl]

right ive found a coversion chart on internet

http://www.convertunits.com/from/bar/to/psi

[PhantomSVE]

The 135Ps is base engine carryover from the 120-125 Ps running the BOSCH VP44.The difference is the FIE(Fuel Injection Equipment) swapped from Bosch to Delphi Common-Rail,Turbo,Flywheel,Adjustable crank sensor and cam sensor added.
The base compression on a Puma 2.4L is 26Bar (382-386 Psi),if you are getting 220 Psi (can not be 220 Bar) and the compression test was done correctly it is to low.
Check the base engine timing,pin crank and cams.Ensure the correct pin is used for the flywheel,if not it will have the wrong crank angle.
Check the vacuum pipes to the variable control turbo as these are often mixed up when major engine work is done on this engine.This will give a misfire,lack of power and smoke.


Let us know how you get on.

[eddydar]

Thanks for the replies guys, yes cam sensor has been fitted wont start without.

The compression test was done and engine was not running. and I got an average of 220 bar about 350 psi

The battery light concerns me as I've recently changed the starter motor, and its been on ever since wondering if I ve left a wire of as I understand that the starter and alternator are connected. Could this be causing my issues shorted out somewere ?? Will check this weekend when the light is better.

Yes used proper pins (extended pip pin for flywheel for tdci) allen key on crank at 11 o'clock, cams pinned at 6 pm.

Bloody annoying thing is that I modified a mondeo cam carrier (a lot of work i wont bore nayone with the details) and had it up and running using it for a few days then a cam nipped and cracked the carrier back to square one. You live and learn...

Just out of interest what are the torque settings for the head on a tdci are they the same as a tddi ?

[angeleye]

Torque setting would be the same. For the head bolts..check in frequently asked questions starter motor wiring as there is a thread on subject..ps...it isnt 220 bar thats over 3000 psi

[karl]

Thanks for the replies guys, yes cam sensor has been fitted wont start without.

The compression test was done and engine was not running. and I got an average of 220 bar about 350 psi

The battery light concerns me as I've recently changed the starter motor, and its been on ever since wondering if I ve left a wire of as I understand that the starter and alternator are connected. Could this be causing my issues shorted out somewere ?? Will check this weekend when the light is better.

Yes used proper pins (extended pip pin for flywheel for tdci) allen key on crank at 11 o'clock, cams pinned at 6 pm.

Bloody annoying thing is that I modified a mondeo cam carrier (a lot of work i wont bore nayone with the details) and had it up and running using it for a few days then a cam nipped and cracked the carrier back to square one. You live and learn...

Just out of interest what are the torque settings for the head on a tdci are they the same as a tddi ?

here

[bambi mk 1]

Thanks for the replies guys, yes cam sensor has been fitted wont start without.

The compression test was done and engine was not running. and I got an average of 220 bar about 350 psi

The battery light concerns me as I've recently changed the starter motor, and its been on ever since wondering if I ve left a wire of as I understand that the starter and alternator are connected. Could this be causing my issues shorted out somewere ?? Will check this weekend when the light is better.

Yes used proper pins (extended pip pin for flywheel for tdci) allen key on crank at 11 o'clock, cams pinned at 6 pm.

Bloody annoying thing is that I modified a mondeo cam carrier (a lot of work i wont bore nayone with the details) and had it up and running using it for a few days then a cam nipped and cracked the carrier back to square one. You live and learn...

Just out of interest what are the torque settings for the head on a tdci are they the same as a tddi ?

220 bar = 3190 psi approx.You would need some starter and battery to churn that over.There is a difference in the injector heights between tddi and tdci cyl heads .Measure down through the injector holes with a calipers.

So your saying it ran ok for a few days with a different carrier and you changed the head it didn't. The heads ARE different.You will get a different injector spray pattern which will cause it to run skite.If you pm me your no I will get back to you

[eddydar]

07720321009, i fitted the tdci injectors in the head and checked for protusion and it was the same.

[eddydar]

been checking the compression tester and its defo 230 bar which is 340 psi, does that sound right, also have a video how do i post it here ?

[MinorMatt]

1 bar is 14.6psi...

so 230 bar would be 3360PSI