EvangelicAtheist · Sep 14, 2019

i’ve completed the 200TDi install into my 90 but I am unable to get it started.

I’ve traced the problem back to the FIP which isn’t pumping any fuel. The FIP was completely refurbished at significant cost before refitting. Nothing at all is coming out of the injector pipes.

I changed the stop solenoid and checked it is getting 12v while cranking (it gets 7-8v but I assume that is okay, it worked fine on the NA). The lift pump is working fine and the FIP is primed. I don’t know what else to try before coming to the conclusion that it’s the FIP itself, but it was rebuilt by a reputable diesel specialist so that seems unlikely.

Appreciate any help or advice as I am right out of ideas.

dieseldog69 · Sep 14, 2019

EvangelicAtheist said:
i’ve completed the 200TDi install into my 90 but I am unable to get it started.

I’ve traced the problem back to the FIP which isn’t pumping any fuel. The FIP was completely refurbished at significant cost before refitting. Nothing at all is coming out of the injector pipes.

I changed the stop solenoid and checked it is getting 12v while cranking (it gets 7-8v but I assume that is okay, it worked fine on the NA). The lift pump is working fine and the FIP is primed. I don’t know what else to try before coming to the conclusion that it’s the FIP itself, but it was rebuilt by a reputable diesel specialist so that seems unlikely.

I did fit a boost pin and spacer, is it possible that I’ve installed one of them wrong and if so would that cause the symptoms?

Appreciate any help or advice as I am right out of ideas.

BP & spakker wont do ought, they only work on Max fuelling.

The pump will have been bench tested when rebuilt.

How certain that there is fuel on priming?

Have you tried fitting a primer bulb after the filter to push the fuel through while cranking?

EvangelicAtheist · Sep 14, 2019

dieseldog69 said:
How certain that there is fuel on priming?

As certain as I can be, although this is my first diesel engined motor so I don't have any experience to go on.

When I remove the fuel inlet banjo there's fuel in the pump, and if I remove the bolt in the centre between the 4 injector pipes and activate the stop solenoid, fuel comes out. Also, if I open up the last fuel return banjo from the last injector, fuel comes pouring out when it is cranked.

dieseldog69 said:
Have you tried fitting a primer bulb after the filter to push the fuel through while cranking?

No, I know what you mean from my outboards but I haven't tried that, but unless I am missing something, it is getting fuel.

dieseldog69 said:
The pump will have been bench tested when rebuilt.

I hear you and which is why I am sceptical it is the FIP but when you’ve run out of ideas and knowledge, you start doubting everything. I do anyway lol

steve2286w · Sep 14, 2019

I recently bench tested my 200 Di, it dint start initially so I primed some more and swapped the lead from a duff battery onto a good 12 v battery and it went straightaway , I could hear the solenoid on the flat battery working so not sure if priming or voltage issue
Is timing ok?

EvangelicAtheist · Sep 14, 2019

steve2286w said:
I recently bench tested my 200 Di, it dint start initially so I primed some more and swapped the lead from a duff battery onto a good 12 v battery and it went straightaway , I could hear the solenoid on the flat battery working so not sure if priming or voltage issue
Is timing ok?View attachment 189653

I think the battery is fine, it is turning the motor over quickly and was working fine when it had the NA in it. I set all the timing up from scratch as I completely rebuilt the motor, and it aint just not starting - I've completely removed the fuel injector pipes so I can see if there is anything coming out from the pump... zip, nada, nowt. Even if timing was off it would be pumping, and it just ain't pumping. Not through the injector pipes anyway, plenty is coming through the return system but I don't know how significant that is.

steve2286w · Sep 14, 2019

http://www.firstdiesel.com/pump-troubleshootingl.htm

If you’re sure you have checked everything I would ask the guys who refurbished the pump

Flossie · Sep 14, 2019

Fuel banjo bolts have different sized ports but look the same when fitted. Fuel flow bolts have a larger hole than the return ones.
I would expect it to still start though just not rev up.
Worth a check, costs nowt?

EvangelicAtheist · Sep 15, 2019

Flossie said:
Fuel banjo bolts have different sized ports but look the same when fitted. Fuel flow bolts have a larger hole than the return ones.
I would expect it to still start though just not rev up.
Worth a check, costs nowt?

Yeah I clocked that. I had replaced the banjos with regular 12mm and then realised the return is restricted so I put the standard ones back in (the right way round). Cheers for the suggestion.

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