Very sick 300TDI

I have a 96 TDI which I have had since 1998, it has never been a performer but seems to have become progressively worse noticeably after
the cambelt change it seemed a bit tight that was 2001.
Because of the poor starting I replaced the Glow Plugs which cured that but then decided to start smoking when accelerating.I tried a heavy dose of injector cleaner but no change. On MOT it could not reach the specified
revs.
I have replaced the Turbo, injectors, cleaned all pipe work plenumn chamber checked leaks in turbo hoses ,checked valve gaps etc. This got rid of the smoke for a few months ,performance still nok. Now it does not idle at all and have had to adjust the throttle cable, it now accelerates like a Greyhound especially through the higher gears but churns out vast ammounts of smoke as the turbo comes in . I have noticed the lack of a clunk of a solenoid when switching on the ignition for quite a while .Is something not activating Please Help

the solenoid clunk you refer to is the heater plugs . try checking the breather pipes i used to have a fiesta van that smoked like a steam train under labour, i sold it in the end cos i coudnt find the fault.

is your injector timing correct was it done proply when your cambelt was replaced could also be your injector pump

Thanks for the suggestion , that was one of my thoughts , it did start to feel less responsive after the cambelt change , also the fuel cutout switch
has metal filings stuck to the plunger which I think points to the fuel pump
cam breaking down. Look like my pockets are about to develop holes.

cooperman63

Thanks for your response, I think there are a few more pipes that need attention .
cooperman63

i have had probs like this in the past try the sedement trap
this causes smoke and loss of power

Thanks Jad

Thats one of the servicing jobs that people tend to avoid, looks like I'm
going under , thanks for the reply

cooperman63

Probably no help at all but just worth checking the flywheel pully as if the key way becomes worn then the timing belt socket fitted behind the pulley can become untimed, usually quite easy to see as the pully will be wobbling

hi does any body now wot diffrence a large intercooler will make on a 300tdi disco

Just fitted a twistedperformance intercooler to our 300 Tdi, it is the direct replacement one that fits in the same space as the Landy intercooler, on it's own I would not like to say that it was worth the £320 but in combination with the K & N filter and the removal of the EGR valve it has certainly made a difference, much crisper and more responsive.

cheers markthefarmer
i'm thinking of getting the full lenth one that fits in front of the rad
like ones from allard on ebay

Good idea - then all you need is the Safari Snorkel to help force the air through the intercooler