sluggish 200tdi

[extreme90]

right the story
today a friend asked for his pump to be tweaked on a 200, no problems i thought  :roll:
cracked the cover off to the diaphram.... lots of a rusty type dust in there  :shock:
so cleaned it all off, then moved on to try and remove the diaphram  :roll:
errm stuck  :shock:
managed to get it to pop up so far but it refused to come out, so i turned it 90 degree put it all back together but it then struggled to pull off let alone move up the road  :shock:
so back off with the cover thinking its already been opend up, put it back together.....nothing still the same  :shock:

so on my understanding of the pump, theres the little throlle shaft that runs on the cam, now if this is stuck in the out position (onto the cam ) then this wont allow me to remove the diaphram...right ?

but if i rotate the cam to its steepest position whilst pulling onit they usualy pop out, but this one doesnt, it goes real tight and still refuses to pull out  :?

now he has always complained that his engine was abit flat, but after today, its megger flat and struggles to pull away  :shock:

so my question is, is it the stuck throttle shaft thats causing the problem ?

i can get to the shaft by removing the throttle arm and them removing the grub screw next to it to gain access to hopefully convince it to become unstuck   but im not looking forward to re-fitting the throttle arm   that springs a royal PITA to re-compress and to alighn the arm back up with the splines all in one hit  :roll:

dan

[Sharpshooter]

Sounds a little pain.

Did you mark up where it was before you moved it? If so, if you reset it, does it go like it did before?

Also, make sure that the hose that is connected to the cover did not split when you removed it.

The throttle pin shouldnt stick if it has been running ok. But i would try filling the void with diesel ad leave it overnight. It might free it up by itself.

 :D

[extreme90]

no, its back to std now and its still the same
pipe isnt split, im getting good pressure out of the tubby
diaphram itself isnt split
it was sluggish before, but never this bad

ive had these pumps apart before and theres physically nothing to break up top end of the pump ( diaphram area)
its when you get inside that things will break  

afink its more to do with the stuck arm than anything  :?
i will find out tomorrow when i take the throttle assay apart  :roll:
but i dont understand why its so flat  :?
dan

[Les Henson]

I agree with Dan - put some diesel in there and leave it to penetrate. Perhaps the reason for the flat engine is down to the mechanism not working properly before you tried to take it apart.


Les.

[Range Rover Blues]

I'd agree, but I'm no expert :oops:

[Little Chris]

Is there any chance that in the repair work some debris could have blocked the injectors?

If so i do know a very good company that recondition them.

[extreme90]

Is there any chance that in the repair work some debris could have blocked the injectors?

If so i do know a very good company that recondition them.

no, its just the blinning shaft sized good    
it still refuses to play
still, can play with it tomorrow in the light which always helps
dan

[solihull-mick]

Ive had this problem a few times now, when the diaphram wont lift out,its the small rod that touches the ramp on the diaphram shaft thats seized, if you remove the throttle lever, but leave the spring on the pump, there is an alen key bung, remove this and you can get to the other side of this rod, lots of wd and a bit of work they free up sweet, when the rod sezies they cause a real loack of power,  ive been fitting a small filter on the pipe from the turbo to the top of the injection pump, to try and stop water and crud entering the fuel pump, also the breather on the rear of the pump can be extended, its a little round rubber thing with a small tube off it,

Ive worked with bosch pumps for many years know and this did stump me the first time i came across it, had it a few weeks ago on chris w`s disco rebuild, did the normal pump trick, instant no power!, rod seized, hope this makes sense  :D

[davidlandy]

when the little rod seizes , does it do this in a particular position, or could it be any position?

I ask this because I reckon that mine may be partially seized as it over fuels all the time on low revs prior to the turbo spooling up and I have tried most things to stop it and i cant get the balance right - theres always smoke no  matter what the power setting

[Range Rover Blues]

Interesting that, Julies has always smoked, though it goes like a stabbed rat.  Even now I've rebuilt the head, it runs quieter, uses a bit less fuel and goes like stink it smokes.

Thing is I didn't do the pump tweak and I don't know who did, it was a quick car when my mate bought it.  It'll give Blue a run for it's money and that's a 3.9V8.

[extreme90]

yep, as i suspected, the actuator had siezed
but the fact that it had worn into the eccentric on the diaphram shows it been like that for w whilst :shock:
there is a 2mm deep groove where its ran  :shock:
no goes like stink, but took me 2 hours to free it  :shock:
dan

[solihull-mick]

when the little rod seizes , does it do this in a particular position, or could it be any position?

I ask this because I reckon that mine may be partially seized as it over fuels all the time on low revs prior to the turbo spooling up and I have tried most things to stop it and i cant get the balance right - theres always smoke no  matter what the power setting

Right that does sound like it has seized in the extra fuel position, clean up and lube up job done :D

[wingy]

Can someone let me know the outcome of this one? I've had exactly the same problems with mine. At first i could'nt move the diahram because the arm was stuck now i have freed it using pointers from earlier in this post but now i'm in exactly the same position! a little trick i found out is to put a thin layer of grease on the shaft and drive the car round the block this shows that the arm is working now as it marks the shaft below the diaphram.

So the arm is working now but i really have no power at all! cant even pull away from standstill!

help please!

[extreme90]

Can someone let me know the outcome of this one? I've had exactly the same problems with mine. At first i could'nt move the diahram because the arm was stuck now i have freed it using pointers from earlier in this post but now i'm in exactly the same position! a little trick i found out is to put a thin layer of grease on the shaft and drive the car round the block this shows that the arm is working now as it marks the shaft below the diaphram.

So the arm is working now but i really have no power at all! cant even pull away from standstill!

help please!

you have a pm with my contact no  

[muddyjames]

would this be worth getting my tame mechanic to do to my disco just as an extra special treat to the disco incase it wants to sieze up? I have no idea where it is under the bonet, I have only heard about the tweeks. I DO NOT want to do the tweeks though. A good clean sounds nicer to my very high mileage disco. :D

[Ja1983]

..if an idiot like me can do it in the rain, in the dark, with just that online guide, and get the result i did - anyone can!

highly recomend it, and as long as your not giddy on the right foot, fuel economy is marginally improved (as it pulls better in higher gears)