landyawd Posted June 2, 2014 Share Posted June 2, 2014 Hi all let me introduce myself, I have been a member for a while now and have found this forum to be very useful. Normally I find what I'm looking for without having to ask. This time however the problem has stumped me.... I have a 200tdi discovery engined challenge truck. Ever since I have owned it when compared to other 200's mine has always been slow. Acceleration is not bad in honesty it's the top end that's the issue. Even on the flag you struggle to get out of 4th into 5th.... No real smoke apart from a bit of grey smoke when cold. I have done the following since owning, and it has made zero difference: New fuel lift pump Cleaned re-seated valves, including new head gasket and full decoke. Regular oil changes New air filter New fuel filter Checked turbo boost running at 0.7-0.8 in the top of third gear, turbo squeals a bit when pulling hard. All hoses replaced Refurbed injectors I guess the only thing left is the fuel pump?? Before I go nuts and spend more money is there anything I could have missed? Quote Link to comment Share on other sites More sharing options...
BogMonster Posted June 3, 2014 Share Posted June 3, 2014 A tweak on the injector pump would liven it up. Details in the Tech Archive. Don't overdo it though. Quote Link to comment Share on other sites More sharing options...
Ex Member Posted June 3, 2014 Share Posted June 3, 2014 Turn the boost up to 1 bar and then the fueling until it is a little black. Is the intercooler clean? Quote Link to comment Share on other sites More sharing options...
landyawd Posted June 3, 2014 Author Share Posted June 3, 2014 Hi guys thanks for the responses, I will check the inter cooler as I have not done that yet. Just read the article about tweeting the furling, fingers crossed that will do it!! Thanks again Quote Link to comment Share on other sites More sharing options...
Tanuki Posted June 3, 2014 Share Posted June 3, 2014 Is the boost diaphragm on the FIP actually doing anything? The mechanism that the diaphragm connects to is known to sometimes gum up and then though the turbo's boosting as hard as it can there's insufficient addtional fuel being signalled bu the diaphragm so you don't make much power. Quote Link to comment Share on other sites More sharing options...
landyawd Posted June 3, 2014 Author Share Posted June 3, 2014 Hi tanuki, never thought of that. Sounds silly is there anyway of testing the diaphragm or will it visually looked gummed up? There is also a pipe running from turbo to the FIP I guess that could cause a similar issue? Quote Link to comment Share on other sites More sharing options...
landyawd Posted June 15, 2014 Author Share Posted June 15, 2014 Well today I took the top off the injector pump, though i would give it a tweak .... This is what I found after undoing the 4 screws! So what do you reckon, considering there should be a star wheel in there, I'm guessing the rest of the pump will be knackered. I presume this is beyond rebuilding? I was thinking about getting an early 300tdi unit to replace it only as they are easier to find... What do you think? Quote Link to comment Share on other sites More sharing options...
Maverik Posted June 16, 2014 Share Posted June 16, 2014 That's been well and truly submerged in water me is guessing somehow... the chamber you see is actually "open" to atmosphere for the diaphragm to work properly, full on breathers have one attached to this too.From the look of it, I doubt you've been getting any boost adjusted fuelling at all going by the look of that. Have you managed to get the control rod out? - it should be attached to the bottom of the diaphragm...I had issues with mine not all that long ago, I posted up some useful diagrams.If you can free it up I recon there may be a bit of life left in it...and link - http://forums.lr4x4.com/index.php?showtopic=85023&hl= Quote Link to comment Share on other sites More sharing options...
landyawd Posted June 16, 2014 Author Share Posted June 16, 2014 Hi Mav, Yes I think your right it's definitely been swimming at some point. The diaphragm was in reasonable condition but is was stuck with the fuel pin refusing to move, hence I undid the retaining nut and to my horror found the previously shown picture. I have rebuilt this truck top to bottom and only just started to investigate the power issues, this must have been the issue from the start I guess. This link http://forums.lr4x4.com/index.php?showtopic=85023&hl= Is really useful great help thanks for that. One evening this week I will attempt to release the fuel pin to see how bad the rot is, I hope I can use it for a while if not I will bite the bullet and get another pump. Quote Link to comment Share on other sites More sharing options...
Maverik Posted June 17, 2014 Share Posted June 17, 2014 Get soaking it with plus gas... a bit of carefully directed heat might see it free... Quote Link to comment Share on other sites More sharing options...
landyawd Posted July 13, 2014 Author Share Posted July 13, 2014 Well I managed to locate an early 300tdi injector pump, bolted straight on and works a treat. It was off an auto so just removed all the throttle position sensor and adjusted the throttle cable. Thanks people for all your help! Quote Link to comment Share on other sites More sharing options...
dave88sw Posted July 14, 2014 Share Posted July 14, 2014 So is it going better now? Quote Link to comment Share on other sites More sharing options...
landyawd Posted July 14, 2014 Author Share Posted July 14, 2014 Oh yes, so much better, to think I was so close to swapping it out for a v8!!!! So glad I didn't!! Just need to sort out my screaming turbo now. It seems a common problem at high revs to get a screaming sound, mine only does it under load, in all gears, it that normal? It still putting out 0.8 to 0.9 bar at the manifold. So I don't expect any performance gain but want to sort it ASAP. Anyone used one of those replacement turbo cartridges? They are about £160 on ebay.... Quote Link to comment Share on other sites More sharing options...
Ex Member Posted July 14, 2014 Share Posted July 14, 2014 It should make some noise. Check for leaks in the plumbing. Quote Link to comment Share on other sites More sharing options...
dave88sw Posted July 14, 2014 Share Posted July 14, 2014 with the engine cold obviously, take off the big inlet hose and grab hold of the centre shaft and give it a wiggle, it should have a little up/down movement but minimal in/out. Screaming noises though are more likely to be a hose as said above Quote Link to comment Share on other sites More sharing options...
landyawd Posted July 16, 2014 Author Share Posted July 16, 2014 Cheers Dave, I'm going to some work on it this weekend, I will report back as what I find. Thanks again Quote Link to comment Share on other sites More sharing options...
landyawd Posted July 23, 2014 Author Share Posted July 23, 2014 Ok it took a while but I got round to taking the inlet pipe off the turbo. I got hold of the shaft and there was a small amount of play nothing to write home about. I have check all the hoses all looks good. Is it possible for the intercooler to make a screaming noise? Any other ideas? Quote Link to comment Share on other sites More sharing options...
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