200tdi Major Problems Continue...

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pos

pos

Well-Known Member
Posts
3,685
Location
West Yorkshire
Hello,

I am still having major problems with my 200tdi with regards to a lumpy idle and plumes of blue / gray / brown smoke on startup. So far I have done:

- injectors reconditioned
- new injection pump
- new timing belt
- new turbo (old one was passing oil)
- new valve guide oil seals
- new lift pump (old one was leaking diesel into block)
- new fuel filter
- k&n air filter cleaned
- oil change

And the bugger is still doing it. Earlier on today I discovered that my injection timing was slightly out, so I adjusted it and I may have gone slightly too advanced (it sounds clattery now) but it made no difference and I still have the rough idle problem.

Also, I have found that air is still getting into my fuel filter housing from somewhere (between fuel tank and lift pump). I know that this might cause the idle problem, but would it cause lots of smoke on startup?

The smoke clears as soon as I give the engine some load, but from a cold start up, with no load, it will smoke away for well over two minutes sound very lumpy / misfiring.

I can't think what else to try,
Any ideas?

-Pos
 
I'm thinking air in fuel line and / or timing out slightly (even though this has been checked). I just can't see air in the fuel line causing so much smoke on startup.

-Pos
 
PaulWilde said:
Sounds like the cylinders/pistons may need a peek at, top rings do go but make no noticable difference to power etc,
Click to expand...

Cheers Paul. That's what I had in mind but there are no signs of engine wear. There is no blow-by and a leakage test came back positive.

-Pos
 
i would do a proper compression test aswell, if your a tooth out on the timing its normally white smoke. if the fuel is airated it just wont run, blue smoke is buring oil, black is over fueling, white is coolant or improper combusted fuel.
 
My RRC used to do this, it was water in the fuel, my problem was a leaking fuel cap allowing ingress of water each time it rained.

Lee
 
bevhelee said:
My RRC used to do this, it was water in the fuel, my problem was a leaking fuel cap allowing ingress of water each time it rained.

Lee
Click to expand...

i was hoping no one would mention that possibility - he's gonna be real ****ed orf having spent sooooooo much money, water/air accumulating and getting via the pickup/sender is the other route into the tank
 
Fixxxxxed it! :D

The plumes of smoke and a lumpy startup were purely and simply down to my injection pump timing being very slightly retarded. I have now adjusted the plate on the pulley so that the pump is a little too advanced (its clattering slightly so I will adjust it back a nats cock) and the smoke has gone. I am now met by the usual slug of black smoke on start up and an immediate steady idle, even today -3 degrees with no pre-heating :)

As for the up/down idle once the engine has warmed up, well I've got my money in this being caused by the air which is finding it's way in between my rubber fuel hose and the solid steel pipe on the lift pump caused by an oval shaped jubilee clip (as a certain person suggested a few months back :eek: ) I'm just sorting out some pipework now.

Thanks everyone!
-Pos
 
pos said:
Fixxxxxed it! :D

The plumes of smoke and a lumpy startup were purely and simply down to my injection pump timing being very slightly retarded. I have now adjusted the plate on the pulley so that the pump is a little too advanced (its clattering slightly so I will adjust it back a nats cock) and the smoke has gone. I am now met by the usual slug of black smoke on start up and an immediate steady idle, even today -3 degrees with no pre-heating :)

As for the up/down idle once the engine has warmed up, well I've got my money in this being caused by the air which is finding it's way in between my rubber fuel hose and the solid steel pipe on the lift pump caused by an oval shaped jubilee clip (as a certain person suggested a few months back :eek: ) I'm just sorting out some pipework now.

Thanks everyone!
-Pos
Click to expand...

Nice one, glad you've finally got her sorted after all this trouble you've had... hopefully you can enjoy it for a while now relatively trouble free :D
 
Langers said:
Nice one, glad you've finally got her sorted after all this trouble you've had... hopefully you can enjoy it for a while now relatively trouble free :D
Click to expand...

That's the plan :) I couldn't believe it this morning when I went to go and fire it up. I was expecting the usual plumes of blue / gray smoke, even though I was hoping that adjusting the timing would help and it bloody worked! I am going to double check that it is all bang on again tomorrow and maybe adjust it back slightly (it's a little too advanced now) and then I will just enjoy it.

Next job: fitting power steering!

-Pos
 
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