300tdi Defender 90 Performance Guidance

narune said:

I have 1995 300tdi D90 with 100K on the clock. With a view to keeping the truck for another 15 years and getting a little more performance out of her, I have spent a lot of time an money this year and have rebuilt the engine (replacing all worn parts along the way), replaced the turbo, added an electric fan, removed the EGR, fitted silicone coolant and intercooler hoses and installed a Twisted Performance Intercooler and done all the tweaks Twisted recommend.

I completed the work over 2 months ago and have now done over 1500 miles (so I assume the engine is now run in) and I am not too impressed with the performance (about the same as before the rebuild), I have noticed a lot of white smoke when the engine is under strain at set off or when travelling up hill and the fuel consumption is about the same.

Apart from spending a load of cash what other mistakes have I done wrong, what have I missed and what can I do to improve performance, mpg and reduce the white smoke?

Cheers,

Ian.
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I'm really hoping that this is down to the mixture being too rich

if you are white smoking then its not excess fuel thats black smoke, its more likely timing is wrong . This results in fuel not being properly combusted . There are other possibles , but this is most likely , as one is low compression .

It could be something as simple as your injection pump timing that is out slightly. Start by setting piston no.1 to top dead centre. My 200tdi has a 'TDC' mark on the crank pulley which aligns with a protrusion on the timing cover casting (I am not sure whether or not the 300tdi has the same marking on the crank pulley) and ensure that you can see the 'lock pin' grove in the flywheel through the wading plug hole on the flywheel housing. If you have a lock pin, insert it to lock the fly wheel into position. On the front of your timing cover, there should be an inspection cover held on with three bolts. Remove the inspection cover and you will see the injection pump drive sprocket. You should also see a tin plate in the centre of the pulley with three bolts holding it in place. Slacken these three bolts a couple of turns (DO NOT remove them completely or bring them close to the end of their threads) and you will find that the plate will rotate both clock-wise and anti-clockwise slightly. Find a 9mm (I think) drill bit and then insert it through the pump locking hole in the pulley and through into the injection pump. If it does not push right through to the injection pump, you need to adjust the position of the pump drive (by way of spanner on large bolt in centre of pulley) so that the drill bit pushes in and pulls out of the hole smoothly with no resistance. Once you have this set correctly, immediately tighten up the three bolts on the adjustable plate and remove your locking pin from the flywheel housing if you fitted one. This will ensure that the injection timing is set correctly. Take it for a test spin.

Is it any better?
-Pos