Still No Power

Hello,

I'm still having major up hill power problems with the disco 200TDi in my 90. There's a big hill near me (Otley Chevin) which I can usually accelerate up in 4th gear up to about 45 mph. At the moment, I'm managing 35 mph tops, which then drops back down to 30 mph when I shift into 4th gear and it's doing my head in. Off the mark acceleration on the flat seams reasonable, although it's not as quick as it was. I can achieve a maximum of about 65mph as opposed to the 75-80 as previous. Can anyone suggest anything else for me to try? So far I have:

- Replaced fuel lift pump
- Replaced fuel & air filters
- Replaced fuel supply line
- Replaced fuel return line
- Adjusted pump configuration endlessly to no avail
- Replaced CAF pipe
- Replaced turbo boost pipes
- Cleaned out intercooler
- Checked waste gate is not stuck open
- Cylinder leakage test - all at or above 95%

I'm running out of ideas fast and it's beginning to really bug me. It kicks out a bit of black smoke as it should when I deck it, just as it does when accelerating up the hill I mentioned earlier. I have also had my injectors tested, all 4 of which were opening at 180 atmospheres as opposed to 200 atmospheres but I've been told this is nothing to worry about. The spray patterns weren't brilliant either but again, not off the wall.

What else can I try?
-pos

Tbh Pos, i have a fair trip to work and back, 50 miles each way...and i noticed some days the power seemed to be down or i was changing down gear where normally i'd stay in 5th..

I think i underestimated how much even a slight headwind affected the performance...or even changes in temperature..i can lose 15mph top end some days...down to 45 where i'd expect 60mph on other days...

Most of my trip is motorway or dual carriageway so i have plenty of time to ponder these things...I did a complete oil and filter change...no difference whatsoever...

storm99 said:

Tbh Pos, i have a fair trip to work and back, 50 miles each way...and i noticed some days the power seemed to be down or i was changing down gear where normally i'd stay in 5th..

I think i underestimated how much even a slight headwind affected the performance...or even changes in temperature..i can lose 15mph top end some days...down to 45 where i'd expect 60mph on other days...

Most of my trip is motorway or dual carriageway so i have plenty of time to ponder these things...I did a complete oil and filter change...no difference whatsoever...

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It's a fair point but I've been traveling up and down that stretch of road through a whole range of conditions and it would always pull at 45 mph or over. I do a lot of motor way miles myself too, traveling between Leeds and Ipswich every 3 weeks or less and I've noticed the power has been down on some of the stretches along there too, regardless of the weather / temperature etc. My old N/A would achieve a similar speed up the chevin - my 200TDi is supposed to be almost twice as powerful! My engine simply isn't 'screaming' like it used to do when I deck the pedal, it's just 'farting' along as so to speak and i've tried everything that I can think of. Maybe I need to get my pump checked and have my injectors reconditioned as a matter of upkeep. At least then I wouldn't have to worry about them packing in for another 150,000 miles or so.

-Pos

Still sounds like timing to me Pos.

Patman1200 said:

Still sounds like timing to me Pos.

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I had wondered that myself, but it wouldn't run as well as it does on the flat if the timing was out, at least I'd imagine not anyway. I did notice yesterday however, that one of my rubber joints on my intercooler top hose was folded back on its self ever so slightly which meant that the pipe was very slightly squashed. I expect that when I'm trying to accelerate up a hill from a stand still, my engine will suck this pipe flat, because my turbo certainly wont be producing the boost that it needs to keep the pipe pressurised from a stand still. Then ofcourse because the engine is struggling, the turbo won't have the flow through the exhaust in order to boost properly. I've ordered a new bit of straight silicone pipe in order to see if it fixes the problem. All being well, it will - fingers crossed!

-Pos

pos, I know that you replaced the fuel line but could it have a reduced flow?

bluehaze said:

pos, I know that you replaced the fuel line but could it have a reduced flow?

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I doubt it, the new pipe is exactly the same bore and it's re-enforced / takes no sharp angles etc. With the pipe between the fuel filter and the lift pump disconnect, it's throwing fuel up at my bonnet at full revs too so that all seems to be alright. The fuel filter is also keeping its self topped up right to the brim too. I'll see how it goes with this new pipe when it comes tomorrow

-Pos

pos, I don't know much about the injector system, but could the timming or injectors have slipped?

bluehaze said:

pos, I don't know much about the injector system, but could the timming or injectors have slipped?

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Hi Bluehaze, I'm well on with sorting the power problems out now and it's looking good so far. I have narrowed the problem down to two things, the first being my boost pipes and the second being my injectors - one of them in particular. I swapped my top intercooler pipes over today and it's made a tremendous difference. The hoses had collapsed internally and one of them was being sucked shut by the engine before the turbo could produce enough boost to force it open or "fatten" it up. I also have one troublesome injector which is making a very clear rattly / tappy sound which is either excessive nozzle wear or a clogged up tip which is preventing the needle from being able to close properly. I am going to try and clean after I remove the nozzle cap tomorrow. It's also developed a leak around the thread where the injector pipe nut screws down and tightening it up makes no difference - it's as tight as it will go without stripping the thread. I'll be putting a new injector pipe on there tomorrow. The other three injectors are also going to be removed in order to have a good clean and an over night soak in some gun wash or other high strength solvent. I'll let you know how it goes when I re-assemble it all on Sunday morning.

-Pos

good luck mate - a couple of more weekends and I'm back on the road too.

bluehaze said:

good luck mate - a couple of more weekends and I'm back on the road too.

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Cheers. What's up with yours?

I removed the bulkhead to get it fixed - one problem led to another, so I stripped it down to the chassis and started again. Just a new rear floor to fit and a problem with the wipers to fix, then it's back on the road.

But at least it started first time.