fitted a new lift pump to my 200tdi 90 today, on the lever it spewed diesel out quite healthily, fitted the in hose and left the one to the fuel filter off and fired the engine, no spewing forth of any expensive stuff.

is it supposed to pump out diesel the same on the cam as with the priming lever? and how can you tell if it's on the cam?

all the instructions just say making sure the arm goes over the cam

Have you fitted the in hose to the right barb? If it was spewing doozle with the lever then as soon as you turned the engine over it should have spewed it too

yep it's the correct one, I followed Busters guide to the letter, but only get a trickle on the cam and still down on power

did you replace all the copper washers and copper olives when doing it? Even a slight air ingress will cause all sorts of problems

yep new washers and olives went in, even checked the fuel lines make sure they are good and not degrading

Has it always been down on power or a fairly recent developement. Have a look at your fuel filter, sedimenter etc?

It sounds to me like you may have installed the lift pump with the cam lever sat beneath or under the cam shaft as opposed to up and in front of it. Remove the lift pump and with the cam lever pointing away from you, place your thumb over the left hand (OUT) union and manually force the cam lever up and down (not the small hand priming lever but the main arm that rides on the cam). It should force air past your thumb. Move your thumb to the opposite (IN) union and it should create a vacuum. Refit the pump being sure that the cam lever is kept up and infront of the cam as soon as it starts to disappear into the cam gallery. DO NOT try and hook the cam lever down and under the cam - that's not how they work. Bolt it back into position. If the cam lever is resting against the cam lobe you will find that it becomes difficult to tighten up. This is very normal, just ensure that you tighten it down evenly to prevent damage to the bolt threads / pump body. Re-connect your fuel lines (fuel in from the tank to the right, fuel out to the filter head to the left) and then turn the engine over on the key. If it is not pumping fuel, you have a buggered lift pump so take it back and swap it for another. They are terrible things at the moment. I have been through 7 within the last two years, most Delphi units, some other makes, each of which have failed in different ways. I have now gone down the electric fuel pump route.

-Tom

it's only recently gone down on power, it was pulling like a train, had a week in Wales, half way round it wouldn't pull the skin off a rice pudding

looks like I'll have it out again tomorrow, make sure it on the cam properly, failing that it's back to get a new one

cheers lads