200TDI down on power, mid range smoke

AdamSanta85

Well-known member
I managed to get the other two washers out of the injector ports with the new set of picks. I would suggest picks with longer stems then what I bought. Cranking the engine to "blow" them out didn't work. Pulling the bonnet made it much easier to get to cylinder 4. I always forget how easy it is to do, and it makes working in the engine bay much more enjoyable.

I think I am about to check/adjust the valve clearance while I am in here. I have never done it.

Also, my truck has the OEM hand throttle. What is the point? To keep RPM up for running equipment off the alternator?

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AdamSanta85

Well-known member
Got injectors back today. The rebuilder said mine were some of the worst he has seen. The insides were all crudded up with carbon build up, not just the tips. After reinstalling, I did a compression test with a HF tester (good value for $30). 400/400/395/385. Weather is super cold right now, so I feel pretty good about those numbers. #4 took a while to build good compression though. I currently have the valve cover off to do an adjustment. Before putting it back together I am going to install new glow plugs. I tried testing the current ones with jumper cables and couldn't get them to glow. #3 and #4 were very dirty. Hopefully have it running sometime before Christmas.

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AdamSanta85

Well-known member
Got her fired up last night. Runs like a different truck. No smoke at all (in the ten minute drive I did), way less smell, much smoother idle and power delivery, way more power both at max rpm and under the curve throughout the entire powerband, and quieter operation. The items changed were rebuilt injectors, valve adjustment, engine mounts, glow plugs.

I can see this engine growing on me. Without another truck to compare to, I never knew how poor it was running, as it always started right up. The way it ran prior it could barely get out of its own way.

I do have some small spill rail leaks at the t fittings and banjo's now. Perhaps from moving the old line out of the way and maybe the constant pressure of the electric inline pump. I ordered the upgraded version of the spill rail to resolve that. I am also going to disconnect the return line and give that good blow through, and or maybe replace that with 5/16 line as well just for my own peace of mind.
 
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