another smoky 200tdi

Hi all, after installing a 200tdi in my series 3 I started it for the first time on the weekend. OK no exhaust and no rad , so I only had it running for around afew seconds, but the bloody smoke (black) and it sounded to be running fast. Now iv had the head off and replaced the H.G and had the head pressure tested ,decoked and the valves lapped. Also new stem seals. New timing belt. It hasn't run for about 8ish years ,should I really be expecting this.

You arent going to be able to tell until you have the rad in and the engine running properly, they always cough out a cloud of black on start up.
Awesome engine in a series.

I've seen people on YouTube with their first start up and its not like any of them. Would to much air in the system or the pump abit out on the timing or stail fuel cause this?

Does the cap on the top of the injection pump diaphragm look like it has been tampered with?
Maybe some one has adjusted the pump good article on here about how to adjust Bosch VE pump have used it myself to set up a 200 without turbo as mine was smoking very badly.

No it looks fine. When I was changing the timing belt I locked the Fuel pump, but by mistake undid the big centre nut.

Even if timing is out a tadge that alone wont cause black smoke.
If it starts immediately it wont be to far out

There is also a adjuster screw, with a 13mm nut on the back of the pump just below the diaphragm, should have a metal collar over it to restrict adjustment, if it hasn't chances are its been played with, this adjusts fuel delivery, and when wound in/up the idle will increase along with amount of black smoke thrown out.

as it is idling high it does sound like someone has played with the injector pump fuel screw the one on the back with the 13mm nut on try loosening the nut and unscrewing this 1\2 a turn at a time as it is very sensitive and see if it makes any difference turn it 1\2 a turn see what that does then another 1\2 etc etc untill you are happy with it.

it is quite common for people to wind these in my tdi was terrible when i first fitted it to my series we wound this screw out and turned the diaphraghm to the steepest part of the metering pin and removed the collar it has since been turned down a bit and the spring preload adjusted as the exhaust gas temperatures where a bit high when we fitted a variable geometry turbo to it

Mine was smokey when first fitted in my 110, 2stroke in the diesel soon fixed it.
The Q