200tdi idles at max rpm

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ProcrastinatorFraser said:
just started it up for the first time and it idles at max rpm... it's only been run for a few seconds so far. any suggestions?
Click to expand...
Is your throttle cable jammed or setup incorrectly?

Has the injection pump been sat open to the air with no fuel in it for a long time? The governor could be jammed thus throwing the pump into max fuel delivery expecting to see the governor back it off.
 
discomania said:
Is your throttle cable jammed or setup incorrectly?

Has the injection pump been sat open to the air with no fuel in it for a long time? The governor could be jammed thus throwing the pump into max fuel delivery expecting to see the governor back it off.
Click to expand...
Thank you ! It has been sat a while, as you say it must be the governer.
 
ProcrastinatorFraser said:
Thank you ! It has been sat a while, as you say it must be the governer.
Click to expand...

Right all is not lost.

The system is now full of fuel so the pump is at least now got some lubrication. Before it comes to taking the lid off (don't panic) you have some options.

You want to manually actuate the throttle and the idle speed from the outside a good few time and quite briskly to try and shock the insides about a bit. If the governor is stuck or the rack is stuck then you could be lucky and it will free off. I would also very gently tap the body of the pump NOT with a metal hammer, but a rubber mallet or leather faced mallet.

Can you try this now?
 
discomania said:
Right all is not lost.

The system is now full of fuel so the pump is at least now got some lubrication. Before it comes to taking the lid off (don't panic) you have some options.

You want to manually actuate the throttle and the idle speed from the outside a good few time and quite briskly to try and shock the insides about a bit. If the governor is stuck or the rack is stuck then you could be lucky and it will free off. I would also very gently tap the body of the pump NOT with a metal hammer, but a rubber mallet or leather faced mallet.

Can you try this now?
Click to expand...
Yep! I'll get to it and let you know the outcome
 
discomania said:
How do you feel about taking the top of the pump?
Click to expand...
That's the answer.

You will need to remove the top section which is the governor housing. As you can see there is a bit to get through first! The throttle control lever needs to be undone so that you just have a shaft to push through the top etc.
You will need to feel confident about it all, but its not difficult, just take your time and take photos as you go if you want, also keep everything very clean. The most difficult part is realigning the throttle lever into the head when you push it back down when you do it back up and that's not bad.

If I was there we could have it all off in 20mins and free off any stuck bits (hoping it's simply a sticky governor or collar) - I don't want to lead you into something you will regret but it is possible and easy enough to do. I don't know your abilities but I think your pretty handy with the spanners if I remember correctly.
 
Well, I've got the top off the injector pump. There is a lever which the throttle arm was connected to, and a pin that runs inside of a cog which will not move at all, is this normal? I'm not sure how these things work...
 
Well i put it back together having not comprehended how any of it worked, and all the throttle seems to be doing is adjusting how quickly the engine spools up to max rpm.... if the idle is set low it will nearly start, but when it does catch it will immediately go to max rpm. If I say the idle high, it will spool up to max rpm almost instantly.
 
Hi Fraser,

Sorry I had to go out.

OK something changed and that is a step in the right direction.

Too bad you didn't post a photo of what you saw. How clean did it all look? Was the metal shiny, or dull and orange tinted? There would have been the governor itself and the governor spring which acts upon a lever which works the rack, this should be free to move back and forth - not a lot, nothing moves that far inside one of these things.
 
discomania said:
Hi Fraser,

OK something changed and that is a step in the right direction.

Sorry I had to go out. Too bad you didn't post a photo of what you saw. How clean did it all look? Was the metal shiny, or dull and orange tinted? There would have been the governor itself and the governor spring which acts upon a lever which works the rack, this should be free to move back and forth - not a lot, nothing moves that far inside one of these things.
Click to expand...
There were 2 kindof rockers attached to one and other. They moved very very freely with no hesitation. All the metal looked very dull indeed with rust on some areas
 
Were you looking at this: https://www.youtube.com/watch?v=zvnQEIcrgWs ?https://www.youtube.com/watch?v=zvnQEIcrgWs

I'm pretty sure you need to take more of the pump apart to get to the governor that discomani is talking about. Like this:
IMG_8518.jpg


https://www.youtube.com/watch?v=zvnQEIcrgWs
 
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