200tdi conversion done and a problem

Got my defender 200tdi engine into my 90 at last to replace my 2.5TD and surprise surprise it started but the fuel lift pump lever does'nt seem to do anything (sloppy) and I obviously should bleed it, after running for a couple of mins I pressed the accelerator pedal and it was struggling and there was a lack of power and wouldn't really rev much then run erratic and cut out, and then got worse at starting and now will not start. I still have the old 2.5TD fuel filter and assemblie on this 200tdi engine and have played around with fuel pipes and jubilees to connect it all up and so am wondering is it that i DO need the 200tdi fuel filter as most people seem to say, or/and is air getting in my fuel pipes as I'm not happy with my connections and it was after adjusting one of these connections it wouldn't start at all. Basically would one or both of these problems cause it to start, but run erratically and finally cut out. Any feed back would be great as I'm a bit dissapointed at the min but if you confirm my suspicions I will get myself a 200tdi filter and hoses asap. Thanks in anticipation Mark.

yep sounds like ya sucking air. fit the 200tdi filter housing. makes life much simpler.

i had the very same problem with mine recently, it turned out to be a piece of insulation tape in the tank that was getting sucked in to the pick up pipe. When the engine was running was there plumes of grey smoke?? check the fuel lines are clear and that you have the intake and return lines connected correctly

Thanks, that pretty much confirms it then, I think I have the lines the right way round got 1 from lift pump to filter and 2 from filter to injection pump but not 100% sure the 2 to injector pump are right way round as no pics or ref of any other 2.5td fuel filter to 200tdi injection pump and the end fittings are totally different. I think the new 200tdi filter is the best option with new pipes as even I CAN'T GO TOO WRONG THEN! by the way what do you think about the lift pump and why there seems to be no pressure there and it certainly didn't raise any fuel with or without air bubbles. Could the pump seeming not to work be tied in with the wrong fuel filter. Thanks again Mark.

sounds like the lift pump is knackerd had the same issues on my 25 na diesel (not 100 % sure but i think the lift pumps are the same, sure someone will come along and clarify) but i had the same probs when out for a drive and it kept dying then would not start at all had to call the AA to get me home in the end replaced the pump and all fine and dandy.

The pumps can be temperamental if the cam isn't in the correct position, if it doesn't have any resitance to the manual pumping, turn the engine over and try again, it usually works.

As for fuel etc, it's a straightforward job to check the lines etc, try loosening the bleed nipple on the fuel pump itself and crank it over ( not too much ) if the lift pump is proving to be a pain. You can go as far as checking each injector, but be wary of the fuel coming out the end of each one as it'll cause some serious damage if it hits you.

If you're not happy with the connections though, sort them out first.

Gonna go and have another play around now but think new filter and lift pump tomorrow! I presume the lift pump is reasonably straight forward to swap over? Thanks again guys.

hawkplasterer said:

Gonna go and have another play around now but think new filter and lift pump tomorrow! I presume the lift pump is reasonably straight forward to swap over? Thanks again guys.

Click to expand...

A straightforward job, 2 bolts and it comes out ( remove fuel lines first ) can be a wiggle to get it back in though