Series 3 200di into series probs

Hi guys changed my engine for a 200di all gone ok i suppose,
But got a problem it's had a bit of black smoke when under load and when you get up to about 45 50 mph it will pop and white smoke
I've had a little play with pump and black smoke not as bad but still not good so am thinking it might be timing belt? Any help would be great thanks guys

Most simple tests first - is it still doing this with no air filter? How many miles have you got on it so far? Clean diesel? All worth looking into before considering the worst.........................................

Jessop661 said:

Hi guys changed my engine for a 200di all gone ok i suppose,
But got a problem it's had a bit of black smoke when under load and when you get up to about 45 50 mph it will pop and white smoke
I've had a little play with pump and black smoke not as bad but still not good so am thinking it might be timing belt? Any help would be great thanks guys

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A little black smoke under load is pretty normal on an old diesel. Wouldnt worry about it if it runs ok, and passes emissions.
Nor sure what you mean by "pop"? And is this a puff of smoke, or prolonged at speed>
Check the pump timing using the timing pins if in doubt.

Do you know if it was running sensibly in its old vehicle, if it was, ask yourself whats different from the old vehicle? the exhaust? the intake? fuel supply? has it been stood for any length of time? is the fuel relatively new?

Have you changed the differentials? Only ask as before I changed mine 60mph was top speed in overdrive and engine sounded like it was about to explode.

Simple way to check timing is take rocker cover off wait for the tappet at the front of the engine to be fully open that will give TDC. Then use a 9mm drill bit in the injector pump timing gear and it should push into the slot a good inch or so.

If the timing is okay then I would say it's a fuel delivery issue. Lift pump on the way out possibly an injector.
Fuel filter you could change as it's cheap. In the series fuel tank there is a filter on the fuel pick up.

Start by checking everything that is free all fuel lines and filters and timing. It cost nothing but time and you won't be any worse of for checking.

Hi guys thanks for replies it's all new filters and fuel I've been driving it for a good few hours now the black smoke seemed to be quite a bit under load
I put a new lift pump on when I got engine noticed it wasn't working guy said engine was good but you never know it was allready out
The diffs are the same but with the petrol engine in it would do 55 60 ok but might be diff with the 200di
And the pop I thinks it's on over run like going down a hill or on to a flat a cloud of white smoke would come out
And I've not tried no air filter yet will do that another thing just sat on the drive reving up it gets to a point and quite a bit of white smoke? Thanks guys it's my first time messing with engines taken me a month to get it in ha

Jessop661 said:

Hi guys thanks for replies it's all new filters and fuel I've been driving it for a good few hours now the black smoke seemed to be quite a bit under load
I put a new lift pump on when I got engine noticed it wasn't working guy said engine was good but you never know it was allready out
The diffs are the same but with the petrol engine in it would do 55 60 ok but might be diff with the 200di
And the pop I thinks it's on over run like going down a hill or on to a flat a cloud of white smoke would come out
And I've not tried no air filter yet will do that another thing just sat on the drive reving up it gets to a point and quite a bit of white smoke? Thanks guys it's my first time messing with engines taken me a month to get it in ha

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Sounds like you are on the right track with that sort of thing. Always possible it could be several small issues, of course, rather than one big one.
Seem to remember some people have had exhaust issues with these conversions, Series exhausts are mostly much smaller bore than Tdi?

Jessop661 said:

Hi guys thanks for replies it's all new filters and fuel I've been driving it for a good few hours now the black smoke seemed to be quite a bit under load
I put a new lift pump on when I got engine noticed it wasn't working guy said engine was good but you never know it was allready out
The diffs are the same but with the petrol engine in it would do 55 60 ok but might be diff with the 200di
And the pop I thinks it's on over run like going down a hill or on to a flat a cloud of white smoke would come out
And I've not tried no air filter yet will do that another thing just sat on the drive reving up it gets to a point and quite a bit of white smoke? Thanks guys it's my first time messing with engines taken me a month to get it in ha

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id set tappets ,check timing then get injectors checked,

Tappets are always a good shout!
Lot of the time people dont seem to bother with em for years!

200tdi well worth checking the crank pulley cannot move on the crank itself, ie variable timing!

I will look at tappets tom do you think the series exhaust would be ok for a di don't have the turbo on.
And the crank pully I didn't know that could change the timing thanks

Jessop661 said:

do you think the series exhaust would be ok for a di don't have the turbo on.

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Very much doubt if a 2 1/4 petrol is going to pump as much gas as a 2.5 diesel. If your original engine was a 6 cylinder it might be ok, they had a bigger bore exhaust.
Doubt if it is the root cause of your probs, but might be contributing.

Ran a 200di for three years now with 21/4" exhaust parts, have high ratio transfer box fitted and exhaust does not restrict power.
I detuned the injector pump to get rid of the smoke when I 1st put it on the road get a little black smoke if I try to accelerate to much going uphill.

Thanks that's good to know my exhaust should be ok what sort of speed you getting out of yours? Mine is black and white smoke messed with pump a bit and the black smoke is not as bad

Not saying it is this with yours but when i fitted my 200 into my s2a swb i treated the engine to a new cyclone breather off ebay and after fitting it i went for a quick spin round the block and covered all of manchester in white smoke so i refitted the old one and everything was ok again, mite be worth looking at it

Ok will have a look at that but now you've put me off getting a new one ha
Set tappets today and crank pully wasn't moving at all noticed water pump pully moves in and out am guessing that's not normal,
So you guys with a 200 in series how do you do your timing belt I wouldn't be able to put the pip in the bellhousing because of the x member? And sounds better with tappets done
Cheers guys sorry for all the qs

Was doing seventy easy but drank a couple of litres of water about 9 weeks ago on a river crossing bent two conrods have rebuilt and is running but higher vibration at present so just running it in at moment had it up to 50mph today accelerating slowly , did a sound check with decibel phone app and is no noisier than before so a little more optimistic that it is going to be ok.
Found bonnet is vibrating so maybe some rubber to reduce the noise , may also loosen the engine mountings and run it to see if they are fighting each other.

So I was going to look at pump timing see if it all lines up so how do you guys do it? I can't get timing pin in bellhousing
I could do with some soundproofing in mine now it's a bit loud now

The turbo boost pipe that did run from the turbo to the injector pump needs disconnecting with a non turbo engine...yes now we all know this....but how did you plug it at the pump end...if you stuck a bolt in the pipe to plug it as some folk do...it can act as a piston and pressurize that pipe...making the pump give max fuel...if that bolt is a good fit it will stay like that...as it heats up pressure will build up in a sealed pipe also.

Apart from that...could be a duff injector.

109 inches is that right about number 1 rocker fully open gives TDC...handy to know.

Just a thought.

Nick

The timing belt is done when you have the woodruff key on the crank shaft lined up with the arrow, the camshaft timing gear has a dot on one of the teeth lined up with the ribbing in the timing case at about the 10oclock position and when you can get the pin/9mm drill bit in the injector pump timing gear at about the 11 o clock position.

However be careful when setting the cam and crank. As the crank turns twice for every one turn the cam makes. So you can have everything lined up as described but the timing will be 180 degree out.

You will need a 30mm socket for the crank pulley bolt to turn it all don't use extra leverage as of the timing is out and you force it something will break. Most important is the cam and crank as the injector pump can be fine tuned when all back together. When it's all set and the belt is tensioned rotate the crank two full rotations. If it rotates freely the timing is good.

Due to the compression of the tdi it might be worth taking a couple of glow plugs out to make rotating it easier.