Need a man who knows 200 tdi engines backwards.

uncle albert said:

Im thinking valve stem oil seals. rocker cover of , nice bright torch, look through valve spring should just see if there ok. if not ok head off im afraid. And no wouldn`t afect compresion

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Head doesn't need to come of for VSS.

Valve stem seals are not going to cause poor pickup or misfiring,if the pump was a s/h one you only have a selllers word for it.The injectors need pop testing by someone who REALLY knows what to look for and if they are OK the pump needs to come off and be checked on a Testbench.

Recheck the timing.
I did a 200Tdi conversion and changed the Timing belt and still swear bliind we did it properly. I would start but run at rev's and loads of blue/white smoke. It was 1 tooth out.

Patman1200 said:

Recheck the timing.
I did a 200Tdi conversion and changed the Timing belt and still swear bliind we did it properly. I would start but run at rev's and loads of blue/white smoke. It was 1 tooth out.

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One of the first things we checked was that it hadn't skipped a tooth on the timing belt. All was timed up propperly but changed belt anyway and it was still exactly the same.
I dont think it could have skipped a tooth as the belt was tight as it should be and like new under the cover, all the marks lined up as well.
If it was one tooth out the problem would be all through the range as it is we have a missfire problem about 2000 revs and it goes like it should up the rev range .

Could it be the wastegate rod, as it was slightly bent where the air filter had slipped down off its bracket and jammed against it.
If so what is the correct adjustment please.

Forget the wastegate rod - its going to be a fuelling issue.

tiny split or pinhole in one of the fuel pipes? try blowing compressed air into system and check for leaks. It sounds like it's sucking air.. from somewhere??

ive had simalar problem befor
it turned out to be the tank sender unit blocked
theres a litle valve in there that gums up and makes it run like its short of fuel
hav you tryed running it from a can piped straight into the filter to elimanate any blokages in fuel line?
thats how i found it

You should get leak off from all cylinders so you have a blocked pipe, a problem with the injector pump or a blockage/air leak somewhere further back along the fuel line. When you changed the injector pump did you renew or at least blow through the pipes that go from it to the injectors? Have you cleaned out the fuel sedimentor (if fitted)?