disco 300tdi flat spot at 3000rpm

the egr was removed when i got it do you have to alter fuel when it is removed not sure if they did it corect

not as far a I know mine is set up as standard.
does yours still have the catalytic converter if so get rid they can also choke the engine.Diesels need to be able to get rid of exhaust gasses quickly to alow them to rev freely and dont like cats.
Is the vacuum pipe from the egr valve blanked off properly ,a screw wont do it as air will get past the threads .
hope this helps.

ye its all blocked off properly and got a stright through exhaust pipe i have tryed all sorts and still cant resolve it it will be something stupid well i hope it is

please can anybody help with this problem

ive been trying to help dave with this one. its really wierd as he says. When you first start it from cold...it will rev well upto 4500+ revs with NO smoke out of the exhaust. But when it start to get warm (we are only talkin 20-30 seconds) it start to struggle reving past 3000 and sometimes 2500 revs. it then starts to smoke out of the exhaust(blueish) and also smoke from the manifold (blueish again) but only at full revs (3000 ish revs). Also noted that the waste rod is impossible to move by hand!!. when the rod is disconnected from the 'waste gate arm' on the manifild there is only about 15mm movement....should there be more????.......

When the engine first starts up(cold engine) the waste gate arm moves when connected to the actuator. When its warm (again 20-30 seconds) there then no more movement????? is this right???

Then enigine pulls like a train upto the 3000 rev mark

i have now replaced the air intake manifold gasket and it still wont rev above 2500rpm when warm but noticed there is a hole in exhaust down pipe could this cause los of power any ideas welcome will try anything

went out today and it drove as it usualy has done for first few miles then realy lost the power on slight hills got to a steep hill and had to keep it in first under 2000rpm doing 10 mph i would be realy greatfull for any help

Dave
My symptons were exteme loss of power ,ie had to be in low range just to start it moving .Tried all sorts .Then for £20 changed the Turdo pipes between it and intercooler and inlet chamber .I did have to re-do the hose clips because they had tightened onto themselves and not the hose.Only a small leak at 2 joints but it made all the difference .Again i had checked these hoses several times and always thought they were OK.
It now has power when moving and plenty of acceleration but still no torque at 0 Mph.I am begining to suspect it might be the kick down cable adjustment limiting the accelerator travel as mine sstops at 2500 rpm which dave ashcroft suggest is the stall speed of the torque converter.
hope this helps

righty ho.... an update...problem solved.....

It turned out to be a blocked fuel line from the tank.

Removed the fuel line off the pump and put a small tyre compressor on it n blew bubble back to the tank...

Re-connected and hay presto...problem solved

yep after all that buying bits and dismantaling it fuel pipe to lift pump was blocked with something just going to clean sediment filter again to see if it went in there but hey if it dose it again ill know what to try first thanks for all the help and info thow it all helped

d_ave2003 said:

yep after all that buying bits and dismantaling it fuel pipe to lift pump was blocked with something...

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EH!

discomania said:

How much diesel is the pump lifting from the tank? Disconnect the outlet side and pump it manually, it should squirt a LOAD of diesel out, no air or anything just pure diesel, if not then suspect an issue in the lines/pickup/fuel sedimenter corroded badly letting in a lot of air, which will reduce the volume of diesel it can pump.

If you get lots of good clean diesel then suspect an issue getting diesel to the injection pump, once you rule that out start thinking pump.

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Aye good you got it sorted in the end.

i know im over the moon now and just got it mot'd so no messing for a few months just the mods to do now but at my own leasure thanks everyone for the helpfull tips and that