200tdi lacking power but with plenty of white smoke

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landylees

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Hopefully someone can help me with a problem with the 200 tdi Defender engine that I have installed in my Series IIa.

The engine starts first time and ticks over nicely. However, it won't do more than a fast tick over even with the throttle full opened - it just pumps clouds of white smoke out of the exhaust.

I suspected that the timing was wrong as I changed the cam belt before I fitted the engine, so I have just checked it. When the key in the crankshaft is aligned with the arrow on the case, the "dot" on the camshaft pulley is aligned with its arrow on the case and the timing pin fits through the injection pump. My only worry is that there is a "dot" on the injection pump pulley and an associated arrow on the case - however, these don't line up but aren't mentioned in any of the manuals or the posts on this forum. I am assuming the "dot" on the on the injection pump pulley can be ignored as the timing pin fits ok when all the other marks are lined up.

I had the engine hanging around for a few years before I fitted it and am wondering whether some dirt has got into it. I did remove a blockage from the fuel return.

Before I take the fuel injection pump to a Bosch service centre, has anyone got any other ideas ?
 
I haven't checked the head gasket but the engine was a good runner (told by a source that I trust), so I am assuming that it is something that has happened in the years between removal and fitting - hence my interest in the cam belt and the fuel injection pump. I did discover the fuel return feed from the injection pump was blocked with muck after I had fitted the engine. I think I will add the head gasket to my list of things to check after the injection pump. Thanks!
 
you can sometimes tell if the head gasket has been leaking by removing the oil filler cap and check to see if the oil looks normal, if it has a whitish tinge and seems creamy then you have water contamination, this can also cause white smoke from the exhaust.
 
White smoke is either unburnt diesel or water.

Assuming you followed what is in this article Defender 200TDI timing belt change - LR4x4 - The Land Rover Forum then it could be the Injection pump timing is out or there is a restriction in the fuel input. Check that there isn't a kink in the fuel input lines and that the fuel filter is clean.
Is the throttle cable actually pulling the throttle on the IP open fully?
If you change the IP timing via the 3 bolts on it and rotating it 1 degree at a time does this help?
Check there isn't a masseeeeve blockage on the air input side, like a mouse nest in the air filter.
I had something similar and it was the fuel filter totally gunged up after a 3 month lay up while I put the engine into my 110. I think all the crap in the tank settled and got sucked up all at once.
 
Right.


If you are using the locking pin method to time the engine, then ignore all the dots.

If you are using the dot method, thes use the dots.

Line up the dots with the arrows, and then fit the belt. I believe the 200 you need to line up the keyway with the arrow - the older ones had a dot stamped into the engine.

This incorrect timing will allow the engine to tick over, just, but as the throttle is opened the pump automatically advances the injection timing a bit, (or it could be retards but i don't think so) so therefore the engine will not run.

The white smoke it unburnt fuel, so the combustion is not happeneing properly, the timing is out.

Hope this helps.
 
Patman1200 said:
White smoke is either unburnt diesel or water.

Assuming you followed what is in this article Defender 200TDI timing belt change - LR4x4 - The Land Rover Forum then it could be the Injection pump timing is out or there is a restriction in the fuel input. Check that there isn't a kink in the fuel input lines and that the fuel filter is clean.
Is the throttle cable actually pulling the throttle on the IP open fully?
If you change the IP timing via the 3 bolts on it and rotating it 1 degree at a time does this help?
Check there isn't a masseeeeve blockage on the air input side, like a mouse nest in the air filter.
I had something similar and it was the fuel filter totally gunged up after a 3 month lay up while I put the engine into my 110. I think all the crap in the tank settled and got sucked up all at once.
Click to expand...


Usually air starvation shows up as black smoke, cos the fuel burns but not cleanly - it would have to be a HUGE blockage for white smoke i rekons!

It could be water in the fuel though, thats also a thought.
 
My project had been stalled for some time (since I last posted) due to work commitments and the birth of my daughter. However, I have had 10 weeks off between jobs and have been able to focus on the Land Rover.

Thanks for all your advice. I have redone the timing belt strictly following the instructions in the workshop manual i.e. do it twice and loosen the injector pump pulley before tensioning the belt, and the problem has now disappeared. When I initially changed the belt, I can only assume I didn't loosen the injector pump pulley and this resulted in a small error in the timing as this enabled the belt to visibly tighten between the injector pump and the cam.
 
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