Thought I'd fixed it but clouds of smoke from 200tdi

Been having trouble with the 90, wouldn't rev above 2000, was lumpy and smoked a bit.
Started and Ticked over lovely though.
Previous to this problem the 200tdi was perfect but the power faded away over about a five mile period and then it would only tick over and rev very lumpy to about 2000rpm with white ish smoke.

Here's what it's not....

Not the head gasket - checked
Not the fuel lines - checked
Not the lift pump - changed it for new one
Not the fuel filter - changed it for new one
Not the injector pump - changed it as the old one was way down on pressure.
Not the cam belt - changed it

Still starts immediately and ticks over but wont pick up propperly, it wont rev and now clouds of white smoke.

Took injectors out today and two were wet and two were dry so I'm thinking that it might need new ones.
It is possible that bits of rubber from an incorrectly fitted pipe from filter to pump may have got into pump and then on to injectors but this is just a theory as the pipe was a hard as concrete and looked to be breaking up inside.

Any theory's greatly appreciated and also anything I may have missed ..

Thank you








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landowner said:

Been having trouble with the 90, wouldn't rev above 2000, was lumpy and smoked a bit.
Started and Ticked over lovely though.
Previous to this problem the 200tdi was perfect but the power faded away over about a five mile period and then it would only tick over and rev very lumpy to about 2000rpm with white ish smoke.

Here's what it's not....

Not the head gasket - checked
Not the fuel lines - checked
Not the lift pump - changed it for new one
Not the fuel filter - changed it for new one
Not the injector pump - changed it as the old one was way down on pressure.
Not the cam belt - changed it

Still starts immediately and ticks over but wont pick up propperly, it wont rev and now clouds of white smoke.

Took injectors out today and two were wet and two were dry so I'm thinking that it might need new ones.
It is possible that bits of rubber from an incorrectly fitted pipe from filter to pump may have got into pump and then on to injectors but this is just a theory as the pipe was a hard as concrete and looked to be breaking up inside.

Any theory's greatly appreciated and also anything I may have missed ..

Thank you

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Click to expand...

Looks like I win then

hows about this for a theory?
couple of injectors stuck open and excess fuel causing white smoke --

couple of injectors not working and causing the missfire and lack of power but what is causing the smoke ---

Going to get injectors reconned anyway and see how we go.

white smoke is excess diesel as its not being burnt properly, so its either over injecting or the pump timing is off - have you used a dial guage to check the pump timing? you say that the headgasket is ok - compression test?

bmp42 said:

white smoke is excess diesel as its not being burnt properly, so its either over injecting or the pump timing is off - have you used a dial guage to check the pump timing? you say that the headgasket is ok - compression test?

Click to expand...

The pump has been just set up with a gauge.

The engine had the same problem with the old pump but much less smoke as pump was fooked so less pressure going to injectors

Checking compressions when I can get a gauge but plenty of resistance when turned by hand.

I'm hoping that the injectors were u/s so I'm having them reconditioned this week.

Think that bits have gone into the pump and goosed it then gone up to injectors - that's what I'm hoping anyway, cant be owt else..

have you tried running it with the air filter to turbo inlet pipe off?

bmp42 said:

have you tried running it with the air filter to turbo inlet pipe off?

Click to expand...

No pipes on it at the moment, it's running without turbo/intercooler and no water in it so it's just burning diesel.
I think 2 injectors may have gone down somehow and that's why it's running rough.
time will tell I'm sure, just open to suggestions at the moment.

Had injectors tested today and they are OK.

Was really hoping that they would be faulty...

SO... checked everything from the fuel tank to the injectors and checked injection timing and fitted new cam belt, checked crank/cam/timing with new belt on.

Engine still running like it is starved of fuel, cracks up straight away and ticks over but give it some throttle and it struggles and wont rev, no power and white smoke.

Dont think it's mechanical as the engine slowly faded over about five miles, power dropping off all the time. No EGR so not that, rockers all going up and down as they should, engine running with intercooler pipe off so not that. inlet sucks yer hand off so not blocked in there

I am going to check that the waste gate thingy isn't blocking the exhaust and that the exhaust itself isn't somehow blocked, maybe a silencer has collapsed inside or something.

Open to suggestions as I'm all out of ideas:doh::doh::doh:.....op2:

Well I had a tip that it may be something to do with the leak off / spill off pipes and fuel return system.
Got to work and renewed the spill off pipes again using new pipe and one piece of clear neoprene pipe between No 1 and No 2 injectors.
Next I removed the banjo off the rear of the pump where the spill off pipes go back to and found a filter inside it. Cleared the filter and blew through the pin hole in the shank with a air line and put it back together.
Started her up and it was a bit better, engine would rev but missing badly at low revs and CHOKING CLOUDS OF BLUE SMOKE.
Well, got the engine to rev at least, tickover fine but smoke problem and missing badly. then I noticed that there was only a small blob of fuel in the clear spill off pipe so I pulled on end of it off and revved the engine until fuel came out of it then put it back. I did the same with the spill off pipe between 3 and 4 revving it until fuel came out.
All pipes back on and revved her up. No smoke whatsoever now , clean as a whistle, just a little black when giving it some serious throttle and nothing on overrun.

So the problem all along was with the fuel return system...after changing lift pump, fuel filter, injector pump and piping and cam belt it was probably the small filter in that banjo coupled with a small split in one leak off/spill off pipe that caused all the problems.

typical isnt it ... but glad you got it sorted now mate , well done mate

sypher said:

typical isnt it ... but glad you got it sorted now mate , well done mate

Click to expand...

Thing is....
Came to it next day and it was back to square one so not fixed after all.

I can fix it every day by revving the nuts off it until the smoke clears but next day is's back to square one.