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Getting Brassed Off Now


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Hi guys

Long storey i bought a used Disco 200tdi engine off the bay a few months back originally to re-ferb myself by stripping it down myself and sending the nesesary bits for recon'd then get them all back and build it all back with new gaskets, seals and anything else it would need like water pump, timing belt, starter motor ect, anyway when I went to collect the engine the guy asked what I was going to do with it so I told him and he said the engine was supposedly been recon'd a couple of years back so shouldn't need doing so once I got it home I decided to part strip the engine, head off, sump and ladder frame off and timing case and back plate off and started inspecting stuff and checking bearing caps for play, everything seemed ok so i rebuilt it back up with new gaskets and seals inc new starter motor, timing belt, water pump and lift pump, anyway came to the part where you start it for the first time in the vehicle ( Defender 200tdi ) and its started immediately and seemed to run ok but not at the stage to road test so just revving slightly in the garage where I found the engine wouldn't rev properly, anyway we gave it a couple of short tests around the block trying to sort the problem but couldn't, came to the conclusion the FIP and injectors need doing.

So last week I had the FIP and injectors done and took it on a 90 mile round trip which it seemed to run great till I came to a steep hill and stuck behind a wagon then once the wagon turned off still on the hill I started to put my foot down through the gears and found when the engine was at full revs and about to change up the engine would die it did this a few times along the trip, anyway I decided over the weekend to take it back to the diesel specialist on Monday ( today ) but at the back of my mind since all this happened something has been telling me its something else and today decided to check all the intercooler pipes and boost pipes for tightness which everything was but I wasn't happy with the elbow intercooler pipe that is fitted to the turbo as all the intercooler pipes are a mismatch of new pipes I bought and pipes supplied with the engine as the elbow pipe looked like it was being pulled and although the hose clip was tight I could just see movement in the pipe where it fits the turbo.

Anyway I couldn't get it any better so I re-rooted the whole intercooler pipe from intercooler to the turbo and it seemed better so decided on taking out for another run and the problem is still there but noticed when I got back home the turbo was leaking oil out of it near to where the big curclip is and oil was coming from some of the joints in the intercooler pipes which I made sure was all clean before fitting them today.

Any idea's please as I am at wits end, part of me is saying its the engine goosed part of me is saying its the turbo goosed.

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200 Tdi's are strong. i would check the oil level and see how much has gone at the turbo. it might just be the turbo seals gone. if the oil pump is working fine you can assume the engine is being lubricated.if theres still enough oil left in the sump, hopefully no real damage would have occurred. it may have just been running like an NA. if you have a compression tester, i'd check the cylinders just as a matter of course.

2nd hand turbo's are available on a well know auction site

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200 Tdi's are strong. i would check the oil level and see how much has gone at the turbo. it might just be the turbo seals gone. if the oil pump is working fine you can assume the engine is being lubricated.if theres still enough oil left in the sump, hopefully no real damage would have occurred. it may have just been running like an NA. if you have a compression tester, i'd check the cylinders just as a matter of course.

2nd hand turbo's are available on a well know auction site

Yeah I have run the engine since and it seems ok, will check the level tomorrow but think most of the oil was coming from the intercooler pipe joint, when I started to remove the intercooler pipes today there was signs of oil in there which made me a bit sus and cleaned them out before I re-rooted the pipe but I remember cleaning the intercooler and inlet manifold out with brake cleaner when I had the engine stripped down a few months ago so I was a bit surprised to see the oil there and even more now and I did top the oil up before I went out today so maybe I have slightly over filled it.

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When i checked the oil level yesterday it was reading on the Low mark so i put 1/2 a ltr in and left it to run down for about 20-30 mins whilst i did something else then came to check it and it hadn't risen much so i put another 1/2 ltr in and set off, anyway just re-checked the level this morning and its showing on the High mark so it looks like i may have over filled it, what do you thing :blush:

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5 hours ago, Cornish Rattler said:

Yeah it's a disco 200 now so shouldn't have that problem with the dipstick, would the leaking seals cause the engine to die when climbing steep hills going up the gears

I'd say not no, oil seals shouldn't stop the turbo from spinning up... unless the bearing has snuffed it too...

Have you had the boost diaphragm open to check that the actuator pin is nice and free?

Do you get any smoke at all when she tops out (looses power)? Is the tubo waste gate free and working properly?

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Is there delamination in the pipe to the turbo? Or is it collapsing under full boost? Mayber a split in the tube from wastegate to FIP or not even attached (been there done that!). Do you have a join in the fuel feed done with a jubillee clip instead of a crimp? Could it be drawing air in extremis? Have you tried a new lift pump incase the current one is a bit weak? 

 

I am guessing you have ruled most/all of them out but just thinking out loud a few things which may affect running as you described.

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7 minutes ago, Orgasmic Farmer said:

Is there delamination in the pipe to the turbo? Or is it collapsing under full boost? Mayber a split in the tube from wastegate to FIP or not even attached (been there done that!). Do you have a join in the fuel feed done with a jubillee clip instead of a crimp? Could it be drawing air in extremis? Have you tried a new lift pump incase the current one is a bit weak? 

 

I am guessing you have ruled most/all of them out but just thinking out loud a few things which may affect running as you described.

Are now then all pipes are new but the fuel pipe is joined with a hose clip at the lift pump and the lift pump is a new Bearmach one so will look at the fuel pipe and if that doesn't sort it I will take it back to the diesel specialist and go from there, cheers guys

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I also remember the diesel specialist saying he has set the FIP to top end power and I mite see a bit of black smoke but there is hardly any smoke at all just slightly when you first go to accelerate then the smoke goes where as before I had the FIP and injectors done it smoked heavily for most of the range, it is also slightly layed back to what I am used to so maybe there is something not quite right :(

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2 hours ago, reb78 said:

I agree on the oil/seals not being the cause of poor running. 

He's had the pump reconditioned, so hopefully the boost diaphragm/pin is free, but it could be worth double checking as Mav suggests.

Whats the gearing?

Gearing not sure what u mean, pump is set to top end power and the gearbox is an lt77 if that helps

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55 minutes ago, Mo Murphy said:

Try the full fuel screw, a quarter turn out Rattler.

Mo

Thing is I don't want to upset anything and loose the warranty on the work that's been done on the FIP and injectors but then again they quoted me £500 but charged my only £400 CASH so have I already lost the warranty anyway, what do you think

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1 hour ago, reb78 said:

Quarter of a turn in (I.e. Clockwise)  isn't it Mo?

I'd speak to the injection pump people before touching it mind. They may well honour their work regardless of how you paid. If not, I'd have a fiddle with it then. 

When you asked me about the gearing was you thinking the FIP mite not be matched to the 1:4 tranny box meaning not enough grunt for the gearing I have or too much grunt for the gearing I have, you have just got me thinking that's all

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It might be in Rich, it's been a while since I last tinkered.

If it hasn't got the guard on it, rattler, then who's to know. As long as you are careful and record what you do. A small change on this screw makes a big difference so small changes only ?

HTH

Mo

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