A few faults for u guys

Hi all - I got myself a 96 plate tdi 300 manual disco - so fAr I've fixed the central lockin - blanked egr - removed cat - serviced it - emptied rear crud catcher by tank - here's the faults I'm left with -
1- don't like starting even wen hot ( I've bought new glow plugs just avnt fitted em yet )

2 - after I'd fitted the new down pipe (cat removal) I seem to ave done somethin to the rev counter as it now bounces around however it feels but I can't seem to find the cable

3- above 3000 rpm it feels like some one is switching the turbo on an off in a haphazard sort of way ?????( it's got the slightly later electronic pump on it )

4 - a few times on tick over the revs dropped to about 400 rpm an no matter wot I do to the accelorator it makes no change untill about 15 seconds have past then the rpm returns to 750 ish an all is ok again (feckin irritating wen u can't go at a green light )

It has got 20 ltrs of high quality bio in 60 ltrs of normal fuel so I don't know if that could be causing some of these probs but kind of doubt it as I ran my navara on it 100% for the last 3 years till it threw a rod

Any help would be realy appreciated as noone seems to b able to help

By the way as for the problem over 3000 rpm I can hear the turbo loud an clear an it don't miss a beat even durin the power loss

rev counter is taken from back of alternator little wire on w terminal you probably knocked doing exhaust,recheck foe air leaks in fuel pipes and sedimenter sounds like lack of fuel

Thanks il take the sedimentor bak off an put some sealer on it to make sure it's not that - thanks m8

run my tdi on bio homebrew-no probs,so I doubt it is your fuel as long as it is good

Is it worth changing the injectors ? It also seems to get worse wen it reaches full temp - is there a way I can check for air leaks ?
Is there a pump in the tank ?
It's doin my feckin head in now - just pickedthe kids up an on the way there it was not too bad but on the way bak it was down on power right through the rev range - can't find any boost leaks - perhaps il check all fuel lines are tight on connections -

Sounds like it is drawing in AIR somewhere AT the tank, of between the tank and the engine bay.

How do I check that ???
I love this landy but hate it at the same time

Take the return off the injector pump-put a clear tube on, and put it in a container,so you can see it-run engine and see what is coming back from this clear pipe-any bubbles no matter how small have got to be dealt with and eradicated.presumably your lift pump is working.
The bio you have,are you sure it is soap free,and not blocking your filter?

i had a similar issue i ran a clear pipe from the lift pump into a can of fuel if that cures it your sedimentor is probably leaking i bypassed mine and carry a spare fuel filter incase of blockages. Not had one yet and i run on about 75% veg oil

If you can get the inspection plate off in the boot floor it's worth checking for dampness round the top of the fuel pump. The pipes have been known to corrode.

Has the same problem with the rev counter when i did my downpipe. There are two wires on the alty in the slot nearest to the engine block, i suspect that one has pulled out of the eyelet connector. simple job to fix.

If you have a manual gearbox car but with a EDC fuel injection pump there's every chance that the pump is where your problems have started. The EDC pump will be looking for signals from the fly-by-wire accelerator pedal - if it's always been a manual 'box car it will have a cable operated throttle pedal.

Just to be sure, has your car, from initial build at the factory, been a manual gearbox car? If it has, then the EDC pump is a later modification. Is the engine the original one?

If you have access to Microcat, you should be able to put the VIN number in and get at the original spec.

Good luck

Dave

Thanks everyone - today I re removed the crud catcher sedimentor thing an resealed it with some suitable gooey gasket in a tube - filledit withfuel an re fixed it - took it for a test drive an to start with it felt the same untill about 4 miles down the road wen it decided to say to me " fxxk you I'm tired an can't b arsed to go an further " so I then had to limp it home at a varying speed of 20 -40 ****ing lots of people off behind me !!!
Once home I removed the fuel filter to find it was pretty much empty - my dad turned the envine over with it off an 1 got 3 splutters of fuel in 8-10 seconds (lift pump?)
refilled the fuel filter with diesel an restarted reved it gently for about 1 minute till it would no longer rev an it cut out - removed fuel filter again with a slight sucking noise (the filter not me) an guess wot it was empty - so I'm off to buy a new lift pump in the morn .....
As for wether it's had a new engine - ain't a clue - I can post the engine no an vin no if that helps anyone who would b kind enuf to find out for me -
had a quick look for the wire for the rev counter but light was not on my side so il have a better look innthe morn once again thanks everyone , il let u know how I get on

Brian S said:

If you can get the inspection plate off in the boot floor it's worth checking for dampness round the top of the fuel pump. The pipes have been known to corrode.

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Ok thanks but this puzzles me , if there's a pump in the tank . How could you be dragging air into the lines bettween the tank and engine bay because the pipes would b pressurized an be pushing air (and maybe some fuel )out of any holes - also , if there's a pump in the tank why is there a manual lift pump ??
I don't get it !!!

Broke it !! said:

Ok thanks but this puzzles me , if there's a pump in the tank . How could you be dragging air into the lines bettween the tank and engine bay because the pipes would b pressurized an be pushing air (and maybe some fuel )out of any holes - also , if there's a pump in the tank why is there a manual lift pump ??
I don't get it !!!

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It's a 300tdi - so the man said anyway.

So I reckon there is not a pump in the tank, but there is a lift pump on the engine.

I sure hope so anyway.

As Charles say's ,there is not pump in the tank-the lift pump on the side of engine drags fuel from the tank-the pipes under the inspection plate above the tank can crack and split and let in air-if you look at your lift pump,some have a top that will come off if you undo the screw,underneath is a gauze that could be clogged-otherwise pump is shagged,not uncommon

300tdi will be lift pump only. However, the fuel pickup in the tank can suck up bits of crud and block under load.
Try running it without the filler cap and see if that makes any difference. Change your fuel filter when you change your lift pump as well.

Cool thanks guys

Well to update - I took the lift pump off an tested it - it's workin fine !!
So iblew the air line down the fuel pipe an heard gurgling an spewing from the back wheel area - I found fuel runnin out the top of the crud catcher - there was a corrosion hole about 6mm wide in the head of the unit - bypassed it - now the truck flies like I thought it should - happy again
till the next puzzle -
thanks everyone