300 tdi Disco Starving.

Hi all, I'm new to the forum but not to Landys, I've got a problem that's driving me nuts.

I picked up a '97 Disco 300tdi a few weeks back, no history & I knew it needed work but it was cheap.

The problem I have is this, it fires up & idles like a sewing machine (albeit a noisy one) runs fine up to about 2500 rpm but when it hits about 3000 it jerks & cuts out momentarily, guffs of whitish smoke too.

Its got a mechanically controlled pump with EGR that looks like it's been blanked.

I'm thinking fuel starvation & it's evident that somebody else has been fiddling with the same idea as the lift pump is pretty recent & seems to flow fine, also the tank's obviously been taken out & refitted.

So I decided to start from scratch & repiped from the tank direct to the engine bay with an inline filter before the lift pump.

Having replaced all the fuel line from tank to injector pump & no improvement I've been scratching my head & swearing.

So today I thought I'd check some other stuff & ran it up with a hand on the turbo output hose, sure enough it's strangling when the boost comes on.

Checked the pipe from the turbo to the injector pump, Eureka it was blown behind the engine.

Replaced it & slight improvement but not a lot.

Any ideas?

timing out??? or pump timing out..

I don't think so as it drives fine below 2500rpm.

Turbo not boosting properly then or worn fuel pump.

Could be I suppose, but doesn't feel like it, turbo's boosting, no black smoke.

Like I say runs sweet as a nut up til the boost comes on then just runs out of juice.

Checked the boost control diaphragm this morning & that's ok.

With no load on, from idle, if you floor it it whips straight to over 4000 before choking, if you run it up gently it starts the odd miss about 2500 & cuts in & out at about 3000.

Everything points to a fuel delivery problem, but not knowing enough about the pump I don't know where to go next.

Frankly it's the last thing I need at the moment, I've got to find a job & I can't use it or sell it as it is.

Help please.

put a clear plastic pipe in between filter and front banjo ooninjector pump you will be able to see if air is entering pump at idle and higher revs ,could easily be fuel pump fact its been looked at dosent mean its right main parts are expensive and maynot have been changed ,if heads worn injection is delayed (retarded)

fuel tank vent?

Sorted.

Some German dick had put a stock banjo bolt in the tank return outlet on the pump instead of the restrictor bolt it should have had.

Scrapper provided one from a dead Citroen, now it goes properly.