Hi, have changed the drained and refilled the gearbox today on my 90 200tdi. After i'd finished, I decided to fit an air filter and fuel filter i'd got recently, as it wouldn't take very long.

Fitted air filter first, easy. Then fitted the fuel filter, was fairly tight but got off easy enough, and then moved on to priming it - the handle on the fuel pump was very limp, and no air bubbles appeared, so i decided to start the engine, as i'd read about that being another way of bleeding any air.

Still had to bleed screw open, but still no air bubbles. Tried revving a little and it struggled and sounded like it was about to cut out.

I then manually filled the filter with some fresh fuel, refitted and still no air bubbles, but engine sounded a lot better.

went for a quick drive, was OK in first but as soon as changed to second, it really started struggling.

turned round, and then was struggling in first. Stopped outside neighbours, put into reverse and it stalled.

I managed to strike it up again straight away (no time has it been difficult to start).

Any ideas? Is it fuel filter or air filter? I've looked at both and they seem OK, but i assume i'm missing something...

also, with the fuel filter not getting any air bubbles nor fuel coming through the bleed screw, doesn't seem right!

If anyones got any ideas, please shout up - i'm hoping it's something small i can fix before work tomorrow - otherwise it's the bus!

the best place to bleed is front banjo bolt on front of injection pump ,filter on tight ,not left old inner seal on filter housing , more likely lift pumps is either on the cam or not working

as above check you havent double sealed it

Cheers for the replies guys, it didn't have the old seal in (i thought i'd checked, but double checked anyway) so tried again and it worked - not a clue why but been for a drive and all is well

Cheers again

Sounds like lift pump is weak or broken especially as manual lever doesnt work at all, the lever is connected to the crank arm, this is exactly how mine went also lost a bit of power, new pump good as gold.


Lynall