200TDI down on power, mid range smoke

AdamSanta85

Well-known member
Last night I pulled off my intake and intercooler piping to triple check everything. Everything looks in order. No torn couplers, all clamps were tight, all piping looks good and clear from obstructions, looking into the intercooler end tanks all looks normal. Compressor wheel on turbo looks OK, no contact with housing, no oil on wheel, shaft play on wheel is minor.

There was a bit of oil in the intake housing from the valve cover recirculation. It wasn't an excessive amount by any means, not enough to concern me. I pulled that hose off while running the engine everything seemed fine, no smoke, no excessive gas pressure. I would consider adding a catch can inline at some point to completely stop the oil from getting back into the intake.

Leaving in 20 minutes to drop off injectors for testing. If I have time I will make my way to HF to get the compression tester to use when the injectors are finished.
 

RiftRover

Well-known member
Another issue I had was a leak in the boost line that goes from the turbo to the IP. This was affecting the fueling at higher boost. The leak was hard to find because the hard plastic tube was cracked on the bottom side of the connection at the IP. Something else you might check.
 

AdamSanta85

Well-known member
Another issue I had was a leak in the boost line that goes from the turbo to the IP. This was affecting the fueling at higher boost. The leak was hard to find because the hard plastic tube was cracked on the bottom side of the connection at the IP. Something else you might check.
I disconnected that from compressor cover and blew into it by mouth. It seemed to hold pressure just fine.
 

AdamSanta85

Well-known member
Hans from H&R Fuel injection just got back to me. All four injectors need a rebuild. $122 per injector including parts and fixing my handy work on the return fitting. I guess it beats $1000 for a new set. He said maybe done by end of next week.
 

JohnsD90

Founding Member
Hans from H&R Fuel injection just got back to me. All four injectors need a rebuild. $122 per injector including parts and fixing my handy work on the return fitting. I guess it beats $1000 for a new set. He said maybe done by end of next week.

That sounds expensive for 200 injectors, but I suppose they are fixing the scoring.
 

AdamSanta85

Well-known member
That sounds expensive for 200 injectors, but I suppose they are fixing the scoring.

Maybe. I explored some other options and this seems to be most cost effective. Other vendors sell rebuilt for $450 a set. I was told $50 per injector extra to fix the scoring so thats $650. New injectors sell for $997 a set shipped, and figure my cores are worth maybe $150 on the market, so $850. He is also local, so no hassle of shipping back and forth, and easy to diagnose any further issues. He seemed to know his stuff and I feel I am in good hands. His specialty appears to be old European diesels. Lots of FIP's and such all over.

Hopefully I fall in love with the 200 when I get them back. For all I know this truck never ran right from the beginning. I have never been around any other Rover's before. It always felt slower then I expected. My buddy has a 4WD dyno. Maybe I will put it on there to see what she puts down.

I wish there was someone local to show me the ropes on tuning the FIP. I don't feel comfortable doing it myself alone the first time.
 

4wdtravel

Well-known member
Another set of eyes on this would be helpful as you have nothing to compare it to. A properly tuned 200 in good shape is very pleasant to drive and would have no problems holding 70+ on the highway.
 

Oilburner

Member
Maybe. I explored some other options and this seems to be most cost effective. Other vendors sell rebuilt for $450 a set. I was told $50 per injector extra to fix the scoring so thats $650. New injectors sell for $997 a set shipped, and figure my cores are worth maybe $150 on the market, so $850. He is also local, so no hassle of shipping back and forth, and easy to diagnose any further issues. He seemed to know his stuff and I feel I am in good hands. His specialty appears to be old European diesels. Lots of FIP's and such all over.

If they are using genuine Bosch nozzles, that's a pretty good price. I have a feeling that a lot of the rebuilt injectors available are using Chinese nozzles.
 

Oilburner

Member
He said the parts were coming from Germany so fingers crossed!

I think that is a good sign. There are also a lot of other good nozzles that aren't made by Bosch - Bosio, for example, made in Italy, or Zexel, which is a subsidiary of Bosch. Even some of the Chinese ones look like they might be OK, but I think spending a few hundred bucks on better nozzles is worth it for longevity. The OEM Bosch ones in my VW TDI went almost 250K miles before I had them tested and they were still very good. They would still be in there if I hadn't fitted bigger ones for more power.
 

AdamSanta85

Well-known member
Any tips for removing washers stuck in the injector holes? 2 of them just wont come out. I have tried getting in there with a hook shaped dental pick with no luck. Cylinders 2 and 4.
 

RiftRover

Well-known member
I used the thing they give you to open paint cans at home depot. The hook part is blunt tho, so if it's stuck you might not be able to pry it loose.
 
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