tearing my hair out!!!! almost bought a renaullt

hello all could anybody help 200tdi
hello im brand new to the forum.I AM CURRENTLY IN THE PROCESS OF RESTORING A 93 DEFENDER 90.SO FAR I HAVE REBUILT THE CYLINDER HEAD ,GROUND IN THE VALVES,REPLACED THE FUEL TANK AND ALL THE FUEL LINES,NEW INJECTORS,NEW FILTER HOUSING AND FILTER,TWO LIFT PUMPS,DELPHI UNIT USED NOW, AND THE ENGINE IS STILL NOT RUNNING PROPERLY! I HAVE BLED THE FUEL SYSTEM AT EVERY UNION AND FITTED CLEAR PIPE AND NO AIR BUBBLES VISABLE. I CAN GET THE ENGINE TICKING OVER FINE FOR MAYBE A MINUTE AND THEN IT DIES AWAY TO A NEAR STALL.IT SEEMS TO ONLY REV TO MAYBE 3500 RPM AND WILL ONLY GO AT 55 60 MPH WITH MY FOOT FLAT ON THE FLOOR,AND WHEN I COME TO AN INCLINE IT DROPS AWAY TO 30 ODD.I AM TRYULY BAFFLED AS TO WHAT IS CAUSING THE PROBLEM. I STILL THINK ITS DRAWING AIR BUT WITH NO AIR BUBBLES VISABLE! IM STUMPT.ALL AIR INTAKE AND TURBO ,VACCUM LINES WERE ALL CHECKED AND FOUND TO BE OK! COULD THIS BE AN ELETRICAL FAULT WITH THE SOLENIOD ON THE FUEL INJECTION PUMP AS I BELIEVE THE FUSE BOX BURNED OUT PREVIOUSLY?

ANY HELP WOULD BE APPRECIATED!
OR MAYBE A LOCAL MEMBER TO KILSYTH,GLASGOW COULD HELP?

Although you've changed 2 lift pumps, it sounds like that is where the prob is to me..

you can remove plunger from solenoid to check ,have you got right banjos in fuel injection pump big hole front small hole rear,if you remove the four injector pipes frompump and get somr one to turn engine over you should get 4 even squirts if not and plenty of fuel get pump checked

See if you can replace a piece of the fuel line with clear pipe and watch what happens when you turn the engine over. You may be getting some air into the lines from somewhere.

http://www.landyzone.co.uk/lz/f8/air-fuel-line-141993.html

this may help...

Oh, yeah....welcome to the looneybin

Not an expert but sounds like injector pump timing is out

firstly thankyou blokes for the advice. I will work through your points next week and ill keep you posted.Reckon ill just change timing belt and reset if required.Ill renew solenoid for fuel cut of switch and badger through the remaining tips from you blokes. oh and ive now bought that renault to travel to work!!!! but my landy aint dead n buried yet

right ive checked timing now replaced timing belt and checked all timing was bang on,which it was. Ive also checked banjo bolt and that was correct. The only thing now is to replace the nozzles on my injectors and see what happens! i pick them up this afternoon! fingers crossed!

new injectors in and no change! new engine time anybody got anysuggestions for an new engine ?

also just done a compression test and it was

no 1 700
no2 550
no3 550
no4 625

is this a normal reading?

Not to sure myself but 2 and 3 look out of sync.
I`m not a 200 expert but are the valve clearences adjustable? Are they right?

Yup I set them to 10 thou when I changed the head gasket! However I will check them again,
I'm tempted to buy another lift pump as I've put a britpart then a derlphi one in and a genuine part is
Next but its more exspensive!
Need to pull my finger out now cause I'm starting to enjoy driving my renault megane too much!

8 thou not 10,

enjoy driving the Renault because when that goes wrong it will cost you an arm and a leg and they are a nightmare to work on. The speedo went on mine. £1200. Renault wanted £1700. Turbo blew £1200. Renault wanted £3500.

Have you tried a direct fuel supply to the injection pump, eliminating the fuel lines, the lift pump and the fuel filter? If you fill a coke bottle with clean diesel and then rig it up to gravity feed the injection pump (tube through tight hole in lid), you will know whether or not there is a problem before the injection pump. When you perform this test, also ensure that you have the fuel return from the back of the injection pump feeding straight into an empty container rather than back to the tank. A kinked / blocked return will cause problems. The Bosch VE injection pump relies on a feed / return pressure balance to maintain internal pump pressures. Does the pump look like it has been tampered with?

-Tom

hi there tried just about everything and cant get the blooming thing running.im going to cut my losses and swap engine. Could someone plz give me some info on sourcing a decent 200tdi replacement unit.

If you could get it down to Yorkshire I would gladly try my best to get it running for you. Alternatively, I would suggest that you have a good look on eBay for Discoveries that are local to you. You should be able to buy a whole vehicle for 5-6 hundred and then you can sell the bits and scrap the body which should see the costs of the engine dissolved.

On the other hand, what stage is it in at the moment? Will it start and idle or will it not start at all? When it does start and run, is the idle smooth or lumpy?
I would strongly suggest that you double check the timing. Also try running the engine with the pipe between the intercooler and the intake manifold removed so that there is a non-restricted supply of air to the engine. I have recently thought that I had air in my fuel but the problem turned out to be my recently reconditioned injectors playing up. If yours are brand new and claim to have genuine Bosch nozzles, I can PROMISE you that they will be exceptionally poor. Where did you buy them from and how much did you pay per injector? I am more than aware that the Bosch nozzles used in these injectors are not fit for purpose. They're currently manufactured in India / Brazil and the spray patterns are atrocious and they will not maintain a steady opening pressure because the needle doesn't seat in the nozzle body correctly. My local diesel specialist is currently working on mine and has gone through 50+ nozzles with no luck. A truck specialist further up the country is also having massive problems with Bosch nozzles used in Scania wagons. They have come down on Bosch like a ton of bricks so there should be a solution in the pipework.

Have yours tested (£5 per injector) and make sure that you can watch the engineer as he / she tests them.

-Tom

jamesmartin said:

8 thou not 10,

Click to expand...

2 thou wont make any difference though mate.

didnt say it did 8 thou is correct though i was only pointing that out

You say its a 200tdi and it wont rev over 3500. Have you checked your turbo actuator? if it is jammed open it will not boost which will account for that problem. Are all your vacuum hoses connected in the right places?

hi there sorry for not mentioning before but i got the nozzles done at a diesel specialist in denny, stirlingshire 200 quid for new nozzles and pressure tested! the engine wont start straight away it takes a good few turns over! ask my poor battery! and once its running it will rev almost to the limit just a bit flat.thats with a new genuine lift pump fitted now! it just dies away when reducing the revs.