Maverik Posted August 1, 2013 Share Posted August 1, 2013 Hi people... Need the brain trust again. LR90 with Disco 200tdi Started seeing a lack of power in the truck, so did my reaserch, changed some hoses, looked for splits in boost actuator pipes etc, then downloaded a heap of material about the VE Bosch injector pump... Checked the boost pressure seems ok and steady at around 0.8-1 bar. Turned my attention to the boost compensator on the inj pump, popped the lid and found the plunger wouldn't come out and was pretty stiff when rotated... after taking the truck for a spin there was no power what so ever. so I figure the wee pin mechanism is seized (#4 on pic)... I've filled the lower section of the diaghram housing with plusgas and poped the top back on and manged to drive it a little to swill it about... and hope the boost pressure would push some of it down the spindal mechanism. Bar removing the pump anyone have a mirical cure for me?... please say you do... Mav Quote Link to comment Share on other sites More sharing options...
Maverik Posted August 2, 2013 Author Share Posted August 2, 2013 Well sleeping on it, I've come up with a plan. Not shown on the diagram is what looks like the access port for actually installing the pin in the first place, its sandwiched between the accelerator return spring mechanism and the diaphragm hosing. so plan is to remove the accelerator cam mechanism and see if I can get access to that bung hopefully giving me access to work the pin back and forth to free it up... plan B will be to remove the top housing completely but want to avoid that if possible. Plan C - I just rang my local diesel specialist and they gave me a ballpark of £300-350 for an overhaul of the whole unit... Mav Quote Link to comment Share on other sites More sharing options...
Gremlin Posted August 2, 2013 Share Posted August 2, 2013 From memory, if you actuate the throttle lever the pin should pop back out, did you try that? G Quote Link to comment Share on other sites More sharing options...
Maverik Posted August 2, 2013 Author Share Posted August 2, 2013 That's the issue, I think the pin is pretty much stuck in one position. I managed to get the truck moving without it stalling, but it was painful to do as you had to slip the clutch so much. I don't think the return springs are that strong as designed to be operated quite lightly. I'll be pulling the top off the guvnor assembly tonight to see what I can do with it. - worst case I can't fix it so I'll have to take it to the diesel place. I'll take some pretty pictures to brighten the post... Mav Quote Link to comment Share on other sites More sharing options...
reb78 Posted August 2, 2013 Share Posted August 2, 2013 Mav, there might be another problem here reading your last post. That number 4 pin increases fuelling as the boost increases. If you are struggling to get going, this is 'off boost' surely so the pins movement wont he relevant to that?? The screw at the very top of your picture sets the 'off boost' fuelling, but that wont affect on the road i.e. in motion performance. Quote Link to comment Share on other sites More sharing options...
Maverik Posted August 2, 2013 Author Share Posted August 2, 2013 From what I can gather the compensator is always active, as if you dial the top lid screw in that increases your fueling pre boost, While trying to remove the cone I'd pushed the pin and got is stuck on the most extreme position for closed. hence the engine would start etc but that was about it. I managed to get to the pin in a round about way or at least the other side of it, I then carfully worked some oil into the piston hole and just kept working it till I manged to get the cone free. i then got a screw driver and bushed the pin through the installation hole then puched it back with anotehr driver from the cone piston hole, filled if full of plus gas and just kept working it till it freed itself up, then owrked it some more to make sure it was free. The cone was coverd with muck and some rust, but also it showed a score where the pin had been acting. popped it all back togetehr and it worked just great. There's a injection pump "tune" thread and a pdf document I found, partlt used this to help me understand how the whole thing works, but also "tweaked" the "rest" screw too to give me more no boost fueling, worked a treat. I'm waiting for my egt sensor to come before I start playing with the other settings. I always shyed away from the inj pump, but after reading into it and working out what everything does its actually a pretty clever and rather flexible bit of kit. I'd certainly recommend everyone with a 200/300 to pop the cover of the boost compensator and to give it a clean/light oil to stop what I found from happening. Becasue I didn;t like the look of the original cone, I went and swapped it out for the one in my spare disco, they looked identical in every dimension so went for it. I then went and popped the one on the camel disco and found although it wasn;t stuck it was not far away, will be looking at the Camel 110 tomorrow for similar things... Mav Quote Link to comment Share on other sites More sharing options...
Damon1 Posted July 3, 2020 Share Posted July 3, 2020 I soaked mine in wd40 n left it soaking with the accelerater wedged open then flicked the pin with a little screw driver until it popped back out it’s working fine now but still under powered a little bit 1 Quote Link to comment Share on other sites More sharing options...
darthdicky Posted July 5, 2020 Share Posted July 5, 2020 I thought the pin which comes in horizontally on mine was stuck in but it turns out it isn’t spring loaded, it’s pushed in by the throttle. Worth noting if you are trying to free things up in there. Rich Quote Link to comment Share on other sites More sharing options...
Jocklandjohn Posted July 6, 2020 Share Posted July 6, 2020 Mine jammed during a pump rebuild and came out of the dealer 'stuck' after they did a test (which it passed) but which caused months of buggeration (loads of smoke, no power, eating fuel) until I actually did what Maverick did and got the manual and read up to try and diagnose the problem. Took cap off, removed diaphragm and found the assembly jammed by the wee pin at bottom. Went back to overhauler and pointed out the problem. *Apparently* (they told me later) they got the horizontal pin out by somehow poking a welding rod into the pump and tacking it on then it took 2 lads to pull it free (w/pump still in vehicle). Then they had no spare pin and Bosch UK didn't have any as "they never need them" (they said), and one had to come from Germany. The pump guys were perplexed and said this was the first time they'd seen this problem. However talking with them a few months later they said another 200di of same vintage came in a few weeks later with exactly the same problem. They had a suspicion that the newer low-sulphur diesel provides less lubrication and this might have some negative effect on the pin. Quote Link to comment Share on other sites More sharing options...
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