Stuck 200tdi Injector Pump

Tbaumer

Well-known member
Just fired up recently swapped 200tdi. Lots of white smoke on start up. First time letting it run more than 10-15 seconds. High RPMs (I did not look at actual on the gauge). Pressing & releasing throttle pedal did not change high RPMs. Thought throttle linkage cable adjustment was holding at high idle, but the lever was sitting on the idle screw & actuating the lever made no change in the idle. Idle screw has not been adjusted from PO. It didn't seem to be full throttle, but uncomfortably high RPMs.
Is there a way to free up a stuck IP? Could this be something else?
 

Napalm00

Well-known member
Could be stuck internally or maybe someone turned the power screw way up...this will raise the idle
 

Tbaumer

Well-known member
Spent a few minutes looking up "Power screw". Is this just the idle adjustment screw? I didn't get any engine RPM response when I moved the throttle cable lever off of the idle adjustment screw & back.
 

Napalm00

Well-known member
Power/smoke screw is In the back of the pump, not the idle stop.

Have you backed the idle stop all the way out and disconnected the cable to make sure it's not holding it open ?
 

Red90

Well-known member
Fill it full of diesel fuel conditioner and let it sit overnight. Try again. Repeat as needed.

Don't play with any adjustments unless you know what you are doing. It is highly doubtful that is the problem.

The way the pumps work is, during starting they inject the full stroke of the plunger (maximum amount of fuel possible). When they get over 500 rpm or so, a set of fly weights then should move the metering sleeve over to the idle position. Any crap in the pump and it gets stuck on the starting position.
 

Tbaumer

Well-known member
Took the top off the boost compensator & found some gunk inside. Cleaned it up with Q-tips & filled it with diesel fuel treatment/conditioner before putting it all back together. I'll wait until tomorrow to crank & circulate it. Since it ran fast & hard, I'm hoping the issue is isolated to the IP & doesn't migrate into the injectors.

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1of40

Well-known member
Yeah, hopefully that crap doesn’t/hasn’t reached the injectors. You may want to just go ahead and install a new fuel filter. Maybe fill it with diesel conditioner while ur at it.
 

Red90

Well-known member
The boost compensator is not really an issue. It is completely separate and sealed from the diesel. There is mean to be grease on the pin.

You want to feed DFC into the pump via the feed line.
 

Tbaumer

Well-known member
... install a new fuel filter. Maybe fill it with diesel conditioner while ur at it.
Did exactly that last night.

The boost compensator is not really an issue. It is completely separate and sealed from the diesel. There is mean to be grease on the pin.
You want to feed DFC into the pump via the feed line.
Okay, so filling the boost compensator with diesel conditioner will do what? Did I mess up? I can grease the pin again (the old grease was pretty hard - I used brake cleaner to remove it).

I plan on cranking it tonight just enough to circulate the treatment through the system.
 

Red90

Well-known member
Okay, so filling the boost compensator with diesel conditioner will do what? Did I mess up? I can grease the pin again (the old grease was pretty hard - I used brake cleaner to remove it).
I would get the DFC out of there and grease the pin. If you drove it and produced boost, you would probably rupture the diaphragm and you would certainly shoot diesel out the breather. That area is meant to be full of air.

Disconnect the solenoid wire.
Remove the line into the pump at the filter. Rig up a funnel to this line. Fill funnel with DFC. Crank engine until DFC drains into injection pump. Let sit.
Hook everything back up and see how it runs.
 

Tbaumer

Well-known member
Started it tonight & the RPMs have improved, still high, but better. Still no throttle cable lever response at all though. Idles rough. Refilled the fuel filter with DFC, disconnected solenoid wire & cranked a bit. I'll try again tomorrow.
 

Uncle Douglas

Well-known member
Damn, worst fears realized. That engine ran well and needed no adjustments when we pulled it from a customers truck a couple years ago when it shipped to you. My guess, fuel has gummed up the pump from the long time that has passed since it last ran. As you noted that pump had not been adjusted. If you pulled the boost pin did you mark the orientation before lifting it and put it back the same ? Hopefully you counted the number of turns you made on the fueling screw on the back of the pump and can return it to where it was ? Best advixe would be to return all adjustments back to where they were and continue the diesel clean treatments.
 

Tbaumer

Well-known member
The boost pin appeared to be the same all around it - not notched on one side like I've seen pics of others, so I didn't think the orientation mattered. I did put the top back on the same way it came off - If that is what you mean. I have not adjusted the idle screw or the fueling screw. So far, I removed the boost compensator with the diaphragm & pin attached, cleaned it, gave the boost compensator a good soaking in DFC :oops:, removed the DFC & greased the pin. Added DFC through the fuel filter & cranking. I did see improvement, I'm repeating this now & again before I leave town tomorrow (until Sunday).
 

Uncle Douglas

Well-known member
The boost pin is tapered and the taper changes significantly as its rotated.
Rotating the profile of that taper changes the fueling rate and smoke dramatically.

Only the aftermarket pins are notched.
 

Tbaumer

Well-known member
The boost pin is tapered and the taper changes significantly as its rotated.
Rotating the profile of that taper changes the fueling rate and smoke dramatically.
Uh oh... hope I didn't spin it, but likely did. This is all new territory for me. What is my next step? Youtube? I'll read up on the threads on the forums the next few days I'm out of town & get better informed.
 
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Red90

Well-known member
Don't worry about it now. If you get the pump running, we can explain fairly easily what position to install it.
 

Tbaumer

Well-known member
No new info update. I have new injectors ordered because of the misfire during high idle. When I pulled the top off the boost compensator & checked the pin, I am now pretty sure I did not rotate it, as it doesn't spin when I tried to turn it by hand. It makes sense to me that the injection pump is gummed up & isn't settling back into a regular idle from the starting full stroke/fuel. I'll continue diesel treatment in hopes it clears it up & the new injectors smooth things out when they get here.
 

Tbaumer

Well-known member
Connected hoses to check the injection pump fuel response & ensure it is clear of debris. Clean fuel in alternating spurts from all four injector feed tubes. One at a time, I removed each injector & cleaned the port before replacing with new.

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