Disco 1 300 tdi 2psi of boost???

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Curt46

Curt46

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Stoke on trent
have just brought a disco 1 160k 300 Tdi auto. EDC. Realise it's not meant to be a race car, but it struggles to reach 50mph. Fitted a boost gauge because I couldn't hear/feel turbo working and I'm only getting 2psi max. Lots of black smoke have replaced boost hoses and cleaned the intercooler. Turbo seems free enough to spin over and only had tiny amount of shaft play. Actuator recently replaced by P/o and wastegate is moving freely.
 
Curt46 said:
have just brought a disco 1 160k 300 Tdi auto. EDC. Realise it's not meant to be a race car, but it struggles to reach 50mph. Fitted a boost gauge because I couldn't hear/feel turbo working and I'm only getting 2psi max. Lots of black smoke have replaced boost hoses and cleaned the intercooler. Turbo seems free enough to spin over and only had tiny amount of shaft play. Actuator recently replaced by P/o and wastegate is moving freely.
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have you checked all hoses from air filter and checked the filter ,i known filters get sucked in to the maf
 
Curt46 said:
have just brought a disco 1 160k 300 Tdi auto. EDC. Realise it's not meant to be a race car, but it struggles to reach 50mph. Fitted a boost gauge because I couldn't hear/feel turbo working and I'm only getting 2psi max. Lots of black smoke have replaced boost hoses and cleaned the intercooler. Turbo seems free enough to spin over and only had tiny amount of shaft play. Actuator recently replaced by P/o and wastegate is moving freely.
Click to expand...
Have you tried another Actuator anyway just in case?
 
Al2O3 said:
Seems free enough? It should move effortlessly, even without oil pressure to the bearings.
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The thing is I thought I was getting pressure, I squeezed the (old) boost pipe while someone revved it up. The pipe went hard, so something was happening just not getting into the motor. Hence cleaning the cooler. But that was at very high rpm. Much higher than I would of expected to be needed.
 
Curt46 said:
The thing is I thought I was getting pressure, I squeezed the (old) boost pipe while someone revved it up. The pipe went hard, so something was happening just not getting into the motor. Hence cleaning the cooler. But that was at very high rpm. Much higher than I would of expected to be needed.
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When you put your finger in the inlet, how easy is it to turn the blades?

Curt46 said:
Are there any approx base settings for number/length of threads showing on the actuator etc.?
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My replacement turbo is still sealed in it's plastic bag. Just clicked a finger nail down the threads and I got 9. Having said that, I've had a bottle of red and a couple of cans of Guinness to water it down a bit. ;)

EDIT
Mine's a 96 plate 300Tdi Defender
 
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Ignore the turbo you have an air/fuel problem, std manual pump 300 with boost sensor pipe (the small one) off will struggle to reach 50mph and thats because lack of boost to trigger the extra fuel needed to get extra boost etc
So assuming its not something silly like blocked fuel/air filters, air being sucked into fuel lines etc you are going to need to get it plugged in to see if theres any codes.
Lift pump working?
Have you removed the sliding plate air flow meter to see if its free and not sticking? Iirc you can get the top off to see the sliding track.

As std they are slow but dependable and the throttle is basically an on/off switch, chipped they really do fly, will give a disco td5 a run for its money.
 
Thanks guys, been out today got a sediment trap and another fuel filter. Going check the rest of the bits suggested. Have brought a ronbox? Didn't want to fit it until cars running right as standard, don't want to mask any issues and cause problems down the line. How do I check if the lift pump is working right?
lynall said:
Ignore the turbo you have an air/fuel problem, std manual pump 300 with boost sensor pipe (the small one) off will struggle to reach 50mph and thats because lack of boost to trigger the extra fuel needed to get extra boost etc
So assuming its not something silly like blocked fuel/air filters, air being sucked into fuel lines etc you are going to need to get it plugged in to see if theres any codes.
Lift pump working?
Have you removed the sliding plate air flow meter to see if its free and not sticking? Iirc you can get the top off to see the sliding track.

As std they are slow but dependable and the throttle is basically an on/off switch, chipped they really do fly, will give a disco td5 a run for its money.
Click to expand...
 
How much fuel should come out of bolt on fuel filter housing? Removed it but nothing came out until car started and ran for a few seconds. Then it just trickled down the side of the pump.
 
Curt46 said:
How much fuel should come out of bolt on fuel filter housing? Removed it but nothing came out until car started and ran for a few seconds. Then it just trickled down the side of the pump.
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Have you checked the fuel pump boost pin and diaphram? Is it moving freely in the fuel pump?
 
Curt46 said:
It's EDC I didn't think it still had a boost pin?
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Oh sorry, didn't realise. Not familiar with this one, but shouldn't be tooooo different to other computer controlled engines. Do you know what pressure the Boost Pressure sensor is reading? Also, have you tried bypassing the wastegate modulator?

EDIT: Just looked and noticed it doesn't actually have one. I got confused with this and the EGR modulator.
 
That is a good point though, is the EGR blanked? If not, the boost pressure may be dumping through to the exhaust.
 
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Thanks for everyone's suggestions. I've changed the sediment trap, fuel filter and wound the actuator rod back. I now have boost and no black smoke . Going to fit the tuning box to sort the fueling tomorrow. But it now drives properly, not actually sure I need the tuning box it goes quite well now.
 
Curt46 said:
Thanks for everyone's suggestions. I've changed the sediment trap, fuel filter and wound the actuator rod back. I now have boost and no black smoke . Going to fit the tuning box to sort the fueling tomorrow. But it now drives properly, not actually sure I need the tuning box it goes quite well now.
Click to expand...

Makes sure it is tuned to it's very best running BEFORE you going throwing go faster stripes at it ...
 
If it responds well to the pedal it may have already been properly tuned, ie remapped
 
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