Loss of oomph II

[spud murphy]

Hi all
Have spent most of today fitting and testing taking off and retesting prior to refitting the following after a sudden loss of all get up and go on a 95 300 TDI ES Auto with 69 on the clock that is now unwilling to rev beyond 2K and has all the get up and go of a warm letteuce.

So after consulting the oracles on here we have:

New sender unit fitted, originals unions were of a puff pastry appearance.

New fuel lines after they refused to be removed from the sedimenter and sender unit. Sedimenter bypassed after it also refused to play nice.

New fuel filter and lift pump.

All lines checked for both pressure and vacuum retention to 1BAR for 1hour each, no leaks.

System primed and starts on the button but will hover and chug around 2K RPM for 20 secs and then top out at 3K.

Induction side all present and correct, wastegate moving and turbo a blowing.

Exhaust was dropped from the downpipe after some one suggested maybe the cat was choked and acting as an engine brake.

So no further fwd to date, have replaced the cheaper and damaged components 1st, can anyone shed any light on which direction to go in next???

Any pointers or tips greatly appreciated, cheers

[lynalldiscovery]

Is it the EDC engine? ie the electric control, if not sure look at the inlet hose between the air filter and the turbo if the hose has a box in it bolted to the nearside wing its the elec engine and will need plugging into testbook or similiar.
If not i would look at injection pump timing first then possibly the injection pump.
Look at the bottom of the timing chest and see if there is lots of rubber dust if so its poss belt is breaking up and maybe slipped hence noe power.


Lynall

[spud murphy]

Cheers Lynal
Nope this is the cable operated engine, so it's time to strip it down and have a gander.
Sorry for late reply just got back from the weekend, Cheers

[littledude]

Boost hose's ok? a leak of bad fitting ones could cause this.

[spud murphy]

Cheers for the replies guys.
This is getting weirder by the day!
Having replaced the entire fuel delivery system upto and including the fuel filter the disco is still starting on the button but laboring around the 2K mark for 20 seconds and then topping out at 3K.
Not convinced about the lack of air and hoping it's not the injector pump I decided to by pass the tank and run the engine from a 2litre clear plastic bottle sat on the inner wing by the brake servo.
So clear silicon hose to the lift pump from the bottle and clear silicon hose from the fuel return to the bottle ie closed loop.
System bled and engine started as normal. After 30 or so seconds the previously see through greenie/yellow diesel has gone opaque ie milky looking and there is bloody air in the fuel feed line!
It looks as though the disco is returning aeriated fuel back to the tank and my bottle is simulating the plastic well in the fuel tank that the sender unit sits in although the gauge is showing half full the fuel out and in lines are pretty close together down in there.
Any ideas guys as to where to start??
When the engine is turned off the diesel in the bottle becomes see through again after less than a minute and there are air bubbles trapped in the fuel feed line???:Bloodymad

[lynalldiscovery]

I remember working on a yacht engine with clear fuel lines and there was a constant stream of air bubbles in the leak off return pipe.

Engine ran okay but after an extended lay up it would not start and had to be bled up again, i assumed all the air collected in the pump causing the non start.

So its either normal which i cant see myself or you are sucking in air.

And with your set up that only leaves two places lift pump or inj pump

Fit the clear pipe between the lift pump and filter housing then between filter and inj pump


Lynall

[spud murphy]

Cheers Lynall
When looking at the spill return pipes they looked a bit tatty and a prime candidate for leaks seeing as they join back at the fuel return union. Replaced them all back to the union and no difference.
However I have noticed that if I pinch the silicon hose returning to my 2 litre plastic bottle 'tank' and then release the hose the small trickle of almost invisable bubbles in the returning fuel is transformed into a frothy surge:eek:

This can be repeated again and again so I think the finger is pointing at the injection pump??
Anyone have any knowledge of the Bosch pump, non EDC model??. Any known leak points??
Apart from all the diesel that has been sprayed and spilt around the engine over the last week there doesn't seem to be any fuel leaks from the pump itself.
Anyone got one knocking about they want to part with?
This is getting desperate now, cheers for any replies:)

[TEMPL4R]

Try disconnecting the boost pipe and block the leak off pipe from the injectors and see if anything happens.

Chris

[spud murphy]

Cheers Chris I'll give it a go in the morning and report back.
John

[spud murphy]

Clamped the leak off pipe on the return leg to the injection pump and removed the boost pipe,still the same.
Looks like the pump??
Anyone know of a good independant or second hand one going anywhere to elliminate the cause?
Cheers all, John

[spud murphy]

I've now bypassed completely any original fuel delivery components and am now feeding the lift pump (which is new) directly from my clear 2liter bottle.
From the lift pump direct to the injection pump, from the pump back to the bottle.
System primes and engine starts, then there is a steady stream of minute bubbles returned to the bottle. This I think is simulating the antisurge well in the fuel tank where the original fuel sender sits, i.e Im taking from and returning to the tank a steady stream of aeriated fuel, engine just as lumpy and unwilling to rev past the 2K mark with my tempory 'tank' as it was with the main tank in line.
Anyone had their injection pump rebuilt??, any good experiances out there??
Any replies very much appreciated, thanks John

[Ray3]

How about you get two bottles and have a seperate one for the return, then see if the engine will rev beyond 2K, is this pos?

[spud murphy]

Cheers Ray I'll have a go tmrww, soaked in Diesel so I'm off up the pub in a mo!

[TEMPL4R]

Have you checked the connection at the pump? Are the Copper washers OK?

Chris

[spud murphy]

Disco 300 TDi ES auto now back on the road and pulling well with not a hint of smoke and all fluids etc intact.
To date it now has
New sender unit, fuel lines, fliter, new lift pump,(cheaper options 1st!) and a rebuilt injection pump plus timing belt kit.


Injection pump was rebuilt for £175 by these guys, real friendly and a very helpfull bunch, highly recommended so cheers Pete and Chris

http://www.ss-diesel-services.co.uk/history.html

(Hope it's allright to put the link up??)

Thanks again all, no doubt I'll be in touch when the next bit falls off!!

Cheers John.