200tdi Issues

[diesel-smoke]

Okay, I have having some issues with my engine, its a 1990 200tdi with 212000 miles covered.

The engine starts fine with a lot a somke but has a misfire when idling.  It also misfires throughout the driving range, and struggles to get to 60 mph uphill / downhill, and if theres a headwind, forget it, 40 - 50 is about tops.

The engine also smokes alot on overrun, or if you change down a gear to get a bit more acceleration from it.  

So far it has had a new turbo, new intercooler, 4 new injectors, timing checked, water pump, fuel lift pump, turbo line to top of fuel pump.

I have also fitted a boost guage to the inlet manifold, which indicates about 0.8 bar of pressure under normal driving.

When standing still the engine revs freely and without problem, right upto about 5000 rpm.  However when driving there is complete lack of turbo assitance as the car tries to climb through the revs, about 3000 is maximum I can get it to.

The smoke is a sort of bluey / grey colour, however it is not using any oil / water, and fuel economy is about 22 - 25 mpg

Anybody any more ideas on what I can check.

Thanks in advance

[beast5680]

is it pressurising the crankcase? may indicate a headgasket problem or worn rings?

[pondy653]

You say you've had the timing checked however, My 200 in my defender was the same. when I stripped out the front timing cover I found the key way in the crank and bottom pulley were both well worn to the tune of about 15 Deg. Replaced the pulley, belt etc, fitted a new key to the crank and it was back to its former power. My 200 has 380k miles on it now so plenty of life left yet.
Tony

[diesel-smoke]

Head gasket was changed a couple of weeks back, along with all new seals, valves regorund, head skimmed etc.  Pistons were all checked at the same time, and nothing untoward was found.

[Range Rover Blues]

Unless they got the gasket wrong I'd say get the timing checked again.

[Ralph]

Sounds to me like low compression

[Pete]

Get the compresion checked. Then take another look at the timing, as Pondy says. Play at the pully will cause problems like yours.

  22/25 mpg is crap for a 200, and it should pull like a train from just over 2000 rpm.

 Have you checked for excessive oil in the pipe from the intercooler to the inlet manifold?
 Might be a good idea to clean out the intercooler, as too much oil in there could lead to the smoke you describe, and the low power. A light smear of oil in the pipe is normal.

 I would be careful about taking the rpm to 5000. I know a few modified ones that will pull that safely.
Then again, I know of a few older ones that have done the hydraulic thing, and reved to destruction on their own engine oil.

 Make sure that you use a really good engine oil. The extra cost is well worth whille.  If in any doubt, try www.difflock.com/forum
They do all the lubricants, fast delivery too.

 On the face of what you say.
 Check the timing again.

 Pete.

[diesel-smoke]

The intercoler and pipes are free of oil contamination, but will get the timing checked again. and see if that solves the problems.

thanks for the advice