robmurg Posted June 20, 2021 Share Posted June 20, 2021 Hi all, long time lurker here even though I don't post much. Hoping someone can help. I've just finished rebuilding a Disco 200TDi that I bought to fit to my ex-military 110. It had damaged bores so I've completely rebuilt it but not touched the fuel injection pump or turbo. I tried the first startup this weekend which was partly successful - the engine is running quite fast with a lot of smoke from the exhaust and the throttle has no effect on the revs either way. This is the first time I've rebuilt an engine so although I've tried to do it right there's always the possibility I've messed something up. Does anyone recognise this problem and have any suggestions for a fix please? Thanks in advance! Quote Link to comment Share on other sites More sharing options...
ballcock Posted June 20, 2021 Share Posted June 20, 2021 These pumps start under full throttle as normal, it appears yours is sticking open. A common problem, there are a number of posts on here covering it. Quote Link to comment Share on other sites More sharing options...
robmurg Posted June 20, 2021 Author Share Posted June 20, 2021 Many thanks, appears I can try running some cleaner through it and if that doesn't work send it for (expensive!) professional attention. I just hope this engine runs as well as the one described by 'Western' when the music stops and my wallet heals up a bit... Quote Link to comment Share on other sites More sharing options...
Snagger Posted June 21, 2021 Share Posted June 21, 2021 If you can cycle hot diesel through the pump, it may free it off. Diesel Bob Tuning is a good company for rebuilding them and injectors. Quote Link to comment Share on other sites More sharing options...
L19MUD Posted June 21, 2021 Share Posted June 21, 2021 I had this on a 300tdi. All I did was repeatedly start it over a few days for a few seconds (it ran flat out!) after 10-15 times it freed itself off and has been perfect ever since Quote Link to comment Share on other sites More sharing options...
robmurg Posted June 21, 2021 Author Share Posted June 21, 2021 Thank you all, a few things to try there. After standing overnight there's no change so I've now filled the pump (via the inlet union from the filter) with Wynn's Xtreme (sic) Diesel System Clean. I'll leave that for a day or two and try again. I have the feeling I will be calling on Mr Diesel Bob before this is all done! Quote Link to comment Share on other sites More sharing options...
steve b Posted June 21, 2021 Share Posted June 21, 2021 If you are going to start it to try and free the pump I'd suggest disconnecting the inlet manifold from the intercooler - no boost = less stress on the engine from cold.... Also reduces the risk of self fuelling on oil mist from breather - been there and it's no fun day at the park......... Steve 2 Quote Link to comment Share on other sites More sharing options...
Ibex94 Posted June 21, 2021 Share Posted June 21, 2021 I had a similar problem with mine only mine would run away if I didn't turn it off. As mentioned above the pumps are design to open at maximum fuel as the engine spins up the governor comes into play and start controlling the engine speed. All these internals are steel so if you've left the engine for a while the small amount of moisture in the fuel can cause these internals to corrode. Even when you think its in a nice dry shed. Had mine rebuilt by local diesel specialist, now looks like new. Also worth a check what are the injector nozzles like? if they're worn you won't get a good pattern and that'll probably generate smoke. The holes in the tip of the injector should be barely visible with naked eye. if you can see them then they're probably worn and worth considering replacing. Where about are you based? Quote Link to comment Share on other sites More sharing options...
vulcan bomber Posted June 21, 2021 Share Posted June 21, 2021 The Bosch VE pump does NOT start the engines anywhere close to full throttle. The governor mechanism has 3 springs to control the fuelling, 1 of these springs, named the start spring lifts the governor off the stop to give a little more fuel than the engine gets for idling on, and this is what gives the puff of smoke at start up. However, once the engine is running this spring is compressed and has no further effect on the engines of running unless you try to stall it. 2 Quote Link to comment Share on other sites More sharing options...
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