lots of black smoke..loss of power and runs hotter after engine swap...help

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mikeNC

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recently replaced my old engine with a 3k mile replacement. first test drive and i have tons of black smoke, noticeable loss of power and runs hotter. sems to be running rich? i have inspected all the turbo hoses (seem fine). new engine was out of an Arkonic 110 1990 200 tdi
 
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1. is the timing set up correctly with new belt/pulleys/tensioner?
2. is the FiP set up correctly to factory standard setting?
3. there's no mention of engine/system mileage - nor when was the last time the complete fuel system was cleaned through, including the FiP and injectors, and changed fuel filters and sedimentor filter to new.

Come back when these have been done and tested
 
v8250 said:
1. is the timing set up correctly with new belt/pulleys/tensioner?
2. is the FiP set up correctly to factory standard setting?
3. there's no mention of engine/system mileage - nor when was the last time the complete fuel system was cleaned through, including the FiP and injectors, and changed fuel filters and sedimentor filter to new.

Come back when these have been done and tested
Click to expand...
thanks for the help

1. no new belts or tensioners..engine was complete
2. I will check this on the weekend
3. 2800 miles on new motor, fuel filter was from orignal motor that was removed and replaced less than 1000 miles ago. previous engine was running well.
 
You need to start off with the basics and ensure timing, FiP are spot on and engine properly serviced. This will give you your correct base point and then clean through the system. Once done you'll know where you stand as this should give no black smoke except for the std 200tdi puff of black at start up.

If engine only on 3k miles, who rebuilt the engine and do you have build sheets showing exactly what was/was not done? It may be the engine was refreshed rather than a proper rebuild, then the 250,000 mile turbo and FiP thrown back on.
 
thanks for the help and i will check those things over the weekend. the engine came out of an Arkonic 110 called the wessex. The defender was shipped to the states and the drive train was removed and a LS was installed. I bought the drive train
 
v8250 said:
You need to start off with the basics and ensure timing, FiP are spot on and engine properly serviced. This will give you your correct base point and then clean through the system. Once done you'll know where you stand as this should give no black smoke except for the std 200tdi puff of black at start up.

If engine only on 3k miles, who rebuilt the engine and do you have build sheets showing exactly what was/was not done? It may be the engine was refreshed rather than a proper rebuild, then the 250,000 mile turbo and FiP thrown back on.
Click to expand...
ok tested....Fip and timing are set. they were in time already but confirmed now. could sitting for two years cause a problem with injector? the loss of power feels like 3 cylinders runniing
 
If injectors were clean/new as part of rebuild, no. It would be worth check them for injector spray pattern by having the injectors cleaned and spray pattern tested. Re' feeling only three cylinders running this could be blocked/leaking injector fuel line, also fuel return line - it's best to remove and inspect these if not new/of known good state. When re-fitting be sure to install new copper injector washer of G-grade, not el cheapo Britpart jobbies.

Q? is the 200tdi in the Arkonic a straight transplant or does the engine have any additional fuel/mixture components? Have Arkonic added a glow plug repay and the relay faulty/stuck permanently on?
 
Something has gone amiss with the install, an airline amiss etc, something is plumbed up wrong, etc

Go over everything again and check, intercooler pipes the lot.

If it was running in the old vehicle, and was taken out and now isn’t something isn’t been connected up right imo
 
flat said:
Something has gone amiss with the install, an airline amiss etc, something is plumbed up wrong, etc

Go over everything again and check, intercooler pipes the lot.

If it was running in the old vehicle, and was taken out and now isn’t something isn’t been connected up right imo
Click to expand...
ill double check tomorrow but i checked the airline that goes from the turbo to the pump and its good, removed and reinstalled the intercooler hoses,...even swapped out the turbo today with the one that was on my old engine. the one that got installed today had less than 1000 miles and functioned fine on the old motor. when i bought this new motor...it was stored in a garage and has been there for two years. was told it ran and the 110 it came out of was onsite. super clean motor and great guy who sold it to me. the motor i installed last ran 2 years ago.
 
v8250 said:
If injectors were clean/new as part of rebuild, no. It would be worth check them for injector spray pattern by having the injectors cleaned and spray pattern tested. Re' feeling only three cylinders running this could be blocked/leaking injector fuel line, also fuel return line - it's best to remove and inspect these if not new/of known good state. When re-fitting be sure to install new copper injector washer of G-grade, not el cheapo Britpart jobbies.

Q? is the 200tdi in the Arkonic a straight transplant or does the engine have any additional fuel/mixture components? Have Arkonic added a glow plug repay and the relay faulty/stuck permanently on?
Click to expand...
appears to be a straight transplant. everything looks similar to my old 200 tdi but just clean and new looking. i do not see any additional relays.
 
v8250 said:
If injectors were clean/new as part of rebuild, no. It would be worth check them for injector spray pattern by having the injectors cleaned and spray pattern tested. Re' feeling only three cylinders running this could be blocked/leaking injector fuel line, also fuel return line - it's best to remove and inspect these if not new/of known good state. When re-fitting be sure to install new copper injector washer of G-grade, not el cheapo Britpart jobbies.

Q? is the 200tdi in the Arkonic a straight transplant or does the engine have any additional fuel/mixture components? Have Arkonic added a glow plug repay and the relay faulty/stuck permanently on?
Click to expand...
would a clogged fuel line result in a lot of black smoke and a loss of power?
 
mikeNC said:
would a clogged fuel line result in a lot of black smoke and a loss of power?
Click to expand...

Loss of power, yes, but I don't think black smoke as engine and FiP set up correctly. Run a by-pass line from the tank to the lift pump, same to the filter and FiP.

Are the intercooler pipes the right way round - top pipe to turbo input, bottom intercooler pipe on the return? Also, is the oil breather separator clean/new?
 
mikeNC said:
ill double check tomorrow but i checked the airline that goes from the turbo to the pump and its good, removed and reinstalled the intercooler hoses,...even swapped out the turbo today with the one that was on my old engine. the one that got installed today had less than 1000 miles and functioned fine on the old motor. when i bought this new motor...it was stored in a garage and has been there for two years. was told it ran and the 110 it came out of was onsite. super clean motor and great guy who sold it to me. the motor i installed last ran 2 years ago.
Click to expand...
Hang on the motor has been stored for 2 years out of a motor?

I thought you had seen it running and then pulled it out and fitted it straight into your car. That’s a bit of a different ball game now tbh.

I wonder if you have faulty injectors?
 
mikeNC said:
would a clogged fuel line result in a lot of black smoke and a loss of power?
Click to expand...
A collapsed air intake pipe certainly could.

When you have checked the air intake hoses, go through the injectors one by one, engine idling, loosening the pipe unions with a spanner at the injector end. You will know which cylinder isn't running properly.

Also, you need to renew the cambelt and tensioners as a matter of urgency.
You don't know how old it is, and a belt that has been sat for 2 years will often break.
 
v8250 said:
Loss of power, yes, but I don't think black smoke as engine and FiP set up correctly. Run a by-pass line from the tank to the lift pump, same to the filter and FiP.

Are the intercooler pipes the right way round - top pipe to turbo input, bottom intercooler pipe on the return? Also, is the oil breather separator clean/new?
Click to expand...
all intercooler pipes are correct, breather is clean and almost new. I'm sure this is a simple error on my behalf somewhere or a fuel issue. the engine was complete when i received it. what's the best way to test if an injector is faulty? I am thankful the help....land rover mechanics are nowhere to be seen in my area
 
v8250 said:
Loss of power, yes, but I don't think black smoke as engine and FiP set up correctly. Run a by-pass line from the tank to the lift pump, same to the filter and FiP.

Are the intercooler pipes the right way round - top pipe to turbo input, bottom intercooler pipe on the return? Also, is the oil breather separator clean/new?
Click to expand...
flat said:
Hang on the motor has been stored for 2 years out of a motor?

I thought you had seen it running and then pulled it out and fitted it straight into your car. That’s a bit of a different ball game now tbh.

I wonder if you have faulty injectors?
Click to expand...
yes. the engine was removed from the arkonic truck 2 years ago with 2800 miles on the drivetrain. it was a complete motor so there was nothing i removed or added to the motor. simply pulled mine and put this new one in. old motor ran fine but had unknown milage and alot of leaks. i have replaced the fuel filter, checked timing on the injection pump, checked the airline from turbo to pump, even replaced the turbo with the one off my old motor (turbo had less than 1000 miles new). i have cracked each injector fuel line and each injector is getting fuel and the engine changes idle as each one is loosened. i have not touched any adjustment screws on the pump. that's where i am today. i am still getting a lot of black smoke, a lot less power an engine would run hot if i drove it much. feels like im getting too much fuel ( my guess)
 
I think you need to start from the very beginning.
Did you use the crank pin to lock into the flywheel? are you sure no1 is at tdc when said pin is installed?
Front pulley still have its timing marks?
Is the crank cambelt gear loose on the crank? these had a habit of coming loose so you had variable valve and inj pump timing, The gear got loose enough that the wedge in the crank wore the crank and the gear away.

Is it an auto? Iirc autos use a different hole in the flywheel housing for the timing pin.

Basically do not assume or trust anything is correct util you have checked it yourself.
 
Re' injectors/as my post above. Were the injectors new when engine was rebuilt? If not/of unknown origin, send them away to get them properly cleaned, rebuilt and spray pattern tested. + if your old 200tdi engine injectors were working fine and not producing smoke use them as test point.

Re' FiP, this must be re-calibrated along with your new timing belt & tensioner kit. As per @Turboman above, timing belt do not like sitting for any length of time as they harden at the pulley and tensioner points. Just go buy a good quality service kit as then you know you're starting from a good/known base point.

Often with these types of faults the fault is a simple one and it's always best practice to start with a clean bill of health at each point, work through methodically and you'll get there.

+ once engine and FiP timing is complete, even if still smoking a little, the first thing I'd be checking is the tappet valve clearances. Again this is an easy task, just remember the rule of nine.
 
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