200TDI down on power, mid range smoke

AdamSanta85

AdamSanta85

Well-known member
This is a continuation of my thread from HERE. I figure its time to start migrating over to this site.

Cliffnotes: Truck is smoking a good bit mid rpm (blackish), full throttle, and down on power, especially up to. Goes flat. It feels like it is starving for fuel or air to me. Top speed is about 60mph now with foot to floor, during the middle of summer I was able to get it up to about 70mph. Once I get into higher RPM's the smoke seems to clear up but power goes flat. Truck starts up right away, idles good, no smoke at idle or while holding a gear on deceleration.

So far I have checked for air leaks, checked timing (belt replaced 2 months ago), replaced fuel feed line, replaced lift pump, installed sedimenter and electric fuel pump. This seems to have helped a bit, but it is still missing something. Engine supposedly only has about 70k on it.

I pulled my injectors last night to get them checked/rebuilt/replaced if need be. One of them was especially gunky looking. This was the second cylinder from the rear (3?).

What do you guys think?

It also didn't occur to me to protect the return line banjo fitting from the wrench until after the injectors were out. I attached a pic of the damage there. The banjo still threads in fine but now I am concerned about the washer sealing. I would be pretty upset to pay to have these rebuilt only to have them leak. I would also be upset if I had to spend $800 on new injectors for an engine I don't really like. Doubly so if it doesn't solve my problem.
 

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javelinadave

javelinadave

Administrator
Staff member
Oily injectors on a gas engine is from a bad injector, leaking piston rings or poor ignition.
Oily injectors on a diesel is from a bad injector or leaking piston rings.
On your motor I would check the compression (pretty much cost free) and if it is good then get the injectors tested. LR 1 wire diesels are not rocket science.
Keep us posted.
 
AdamSanta85

AdamSanta85

Well-known member
javelinadave said:
Oily injectors on a gas engine is from a bad injector, leaking piston rings or poor ignition.
Oily injectors on a diesel is from a bad injector or leaking piston rings.
On your motor I would check the compression (pretty much cost free) and if it is good then get the injectors tested. LR 1 wire diesels are not rocket science.
Keep us posted.
Click to expand...

Thanks bud. I wish I thought to check compression prior to yanking the injectors. No doubt my injectors are in need of rebuild being nearly 26 years old, but I won't really know if that is ALL it is until I do compression check. If my cylinder is bad I am binning the engine and saving for an LS. It pains be to put money into something with 109hp.
 
4

4wdtravel

Well-known member
I'll take it from your scrap bin! :)

Worth noting summer/winter diesel is different but should not cause that much of a difference. Worn rings are also not usually a quick onset problem.

Headgasket failure leaking compression, boost leak, clogged air filter.... seems like you have worked through some of those.
 
AdamSanta85

AdamSanta85

Well-known member
4wdtravel said:
Worth noting summer/winter diesel is different but should not cause that much of a difference. Worn rings are also not usually a quick onset problem.

Headgasket failure leaking compression, boost leak, clogged air filter.... seems like you have worked through some of those.
Click to expand...

Air filter is fresh.

No oil in coolant, no coolant in oil, no pressure under the oil cap while running, no black smoke from breather so hopefully not a HG...

Boost gauge shows boost, new silcone couplers are tight. I doubt it is that...

After a nice conversation with Mr. Robert Davis, I am going to drop them off to get tested tomorrow at H&R Fuel Injection in Bohemia NY, and also try to find a compression tester I can borrow.
 
AdamSanta85

AdamSanta85

Well-known member
4wdtravel said:
Check the back of the block, behind the #4 cylinder, for a compression leak to atmosphere
Click to expand...

Ill try and use a mirror to look back there for any evidence of a leak. Since the injectors are out, they aren't going back in until they get passing marks. Injector #4 looked normal though. I'll update this evening.
 
AdamSanta85

AdamSanta85

Well-known member
4wdtravel said:
You said the boost gauge is showing boost - how much boost exactly?
Click to expand...

12psi IIRC. Gauge is T'd in the wastegate line, so I guess I don't really know for sure it is getting to the intake manifold, but I am pretty confident it is. When I got the truck it had a big boost leak and I could hear it. Replaced all couplers with a silicone kit that are nice and tight. I hear the turbo come on but power goes flat. It REALLY feels like a fuel thing.
 
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javelinadave

javelinadave

Administrator
Staff member
Is there any play in the turbo cartridge or is it tight? A worn out turbo would give you the flat power symptoms you are experiencing.
 
AdamSanta85

AdamSanta85

Well-known member
javelinadave said:
Is there any play in the turbo cartridge or is it tight?
Click to expand...

It has a little bit of shaft play wiggling from the compressor cover side, but not terrible. Haven't pulled the downpipe to give it a real shake. I used to sell turbo's and have felt my fair share of blown ones. Compressor blades look OK. I think if it was drinking oil out the exhaust I would see noticeable oil consumption and it wouldn't stop blowing smoke at high RPM.
 
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RiftRover

RiftRover

Well-known member
I had similar symptoms and it turned out to be over fueling. Spent a lot of time tuning the IP and I posted about it on the "other" site. If you haven't done any tuning you need to do your research and do it. Best thing i ever did with my TDI and wish I had done it sooner. I would start with new injectors tho and it looks like you are already planning to do that. Just FYI, your cores will probably not be accepted with that damage, or you will have to pay to have them machined (ask me how i know... :rolleyes:) I can send you a document that describes how to tune the pump if you want (I can't seem to upload it here). There are several versions out there if you look for it.
 
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