Problems 200tdi

Hi, can anybody offer any advice. I’ve just had a full service, new intercooler (Allisport) and radiator but it is now missing at high revs, over 2000 rpm. Ecspecially in forth and fifth gears. What could the problem be?
It has recently had a new lift pump and had a boost pin fitted.

Standard sorts of checks, Check you've plumbed the lift pump in properly. Change the fuel filter, check for air in the fuel pipes, that you're getting fuel at all the injectors, that the air filter is good and all pipework clean inside and not de-laminated or split. Check timing, check throttle cable hasn't moved and is giving full movement. Does it rev out properly when stood? 2k is about when the turbo is giving boost properly (1800+rpm) so check the turbo is working and that the pipes to it are clean of oil, and not split.

When did it start to run poorly? After the lift pump fitted?, After the boost pin fitted or after the intercooler and rad fitted?

As above really. Nice reply Paul

Paul D said:

Standard sorts of checks, Check you've plumbed the lift pump in properly. Change the fuel filter, check for air in the fuel pipes, that you're getting fuel at all the injectors, that the air filter is good and all pipework clean inside and not de-laminated or split. Check timing, check throttle cable hasn't moved and is giving full movement. Does it rev out properly when stood? 2k is about when the turbo is giving boost properly (1800+rpm) so check the turbo is working and that the pipes to it are clean of oil, and not split.

When did it start to run poorly? After the lift pump fitted?, After the boost pin fitted or after the intercooler and rad fitted?

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Paul, It started to run poorly after the boost pin, intercooler and radiator was fitted. On tick over it’s fine.

When it's on tickover, will it rev out if you try?
When it's running will it get to higher revs if you just ease the throttle up?
I'd change the boost pin back to standard and try it again ... make sure the engine is running properly at higher revs before trying to make it go faster ..

Paul D said:

When it's on tickover, will it rev out if you try?
When it's running will it get to higher revs if you just ease the throttle up?
I'd change the boost pin back to standard and try it again ... make sure the engine is running properly at higher revs before trying to make it go faster ..

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Paul, sorry for the late reply. Yes it does rev out on tickover. Just over 2000 rpm and just under 1 bar on the boost gauge

Can anybody advise.

I have a 1992 defender 90 200TDI. In the last two month I have had a new galv chassis, Allisport intercooler, fuel pump, lift pump, new radiator, timing belt, full service etc, etc.

On hills in the lake District over the weekend I am struggling with for power, 1st gear is screaming and 2nd gear isn't enough power to go up the hill.

On the motorway the same, struggling to get to 60mph but when i hit a hill (Shap) fourth gear screaming.

I have spent a fortune but need help, is there any people who can tune these 200 tdi to get more power, I have seen various people offering kits i.e Allard but I dont know if they would help, OR to a bite the bullet and go for a engine swap. If so what??
300 tdi, TD5 or the cummins 5.9 ?

I really want the vehicle as a 2nd car for greenlaning.

last question, for getting up the hills, is it more torque or BHP that is needed?

Thanks

Shaun.

Did you solve the misfire issue?

As suggested above you need to make sure everything is working as it should before modifying for more power. A standard 200Tdi is more than adequate for any road in the UK and should hold over 60mph going up Shap no problem, and do well over 70mph on the flat.

Have you got standard drivetrain components (gearbox, transfer box, diffs, tyres etc) or is it modified?

Yes, I sorted the mis - firing. I took the boost pin out and fitted a new fuel pump, lift pump and replaced timing belt. Could it be the turbo?

As I am aware it is all standard drivetrain.

Definitely can't get 70 mph, simply not possible at this moment.

I'd re-check all the pipework between the air inlet, turbo and intercooler. Standard pipes can de-laminate inside over time and still appear good, but under pressure a flap drops, cutting air supply.

However, from your post, "On hills in the lake District over the weekend I am struggling with for power, 1st gear is screaming and 2nd gear isn't enough power to go up the hill. On the motorway the same, struggling to get to 60mph but when i hit a hill (Shap) fourth gear screaming. On the motorway the same, struggling to get to 60mph but when i hit a hill (Shap) fourth gear screaming." .... Sounds like the clutch is slipping! Maybe gearing is too low .. or the opposite of too high!!

To clarify, "1st gear is screaming and 2nd gear isn't enough power" .. are you sure the handbrake is releasing, that all brakes are releasing, and that the drivetrain isn't properly nackered and that it is standard? Is this onroad or laning? Are you stuck in low box? Have a look underneath at the transfer box, there is a number on a sticker that will say 1.2, 1.4 or 1.6, what does yours say? What size tyres do you run? Any changes to the diffs, ie lockers fitted? If so, do you know what the CW&P gearing is? If you don't understand that don't worry ..

Just a thought I had a disco 200 I put into my then 90 before I put the engine in I replaced the fuel solenoid as a matter of course anyway had loads of probs trying to get it to rev up properly and in the end took the 90 to have the injectors and inj pump looked at and after they was fully recon'd the problem was still there so took it back and they ended up replacing the new Bearmach fuel solenoid for an all makes one I think and it cured it so for a few quid I would suggest replacing the fuel solenoid, hope this helps