C

Coopers100

Member
Hi guys new to here. Just wondering if anyone could possibly give me some ideas for test running my engine which is only in a rolling chassis and as no bulkhead yet just want to check for oil leaks etc I have set up the radiator and the fuel tank and the exhaust any help would be much appreciated thanks
 
What engine?
200/300 just needs one wire to run, td5 I have no idea, v8 I cant afford one!
 
Just one wire from battery positive terminal to the terminal on the back of the inj pump, will keep her running.
I assume you have battery hooked up to the starter?
If not a pair of jump leads will do the trick, battery negative to the engine block with one lead, battery positive to the fat temrinal on the starter motor solenoid (not the braided strap) then using a piece of wire connect the jump lead to the solenoid to the small spade terminal on the solenoid and she will crank over, to stop it cranking just remove the small wire, and to stop the engine just remove the other wire from the inj pump.
Literally 5 mins work.

Always worth having someone on the battery connecitons, so if you get worried, or it tries to eat you, simply removing the leads will stop everything dead in its tracks.
 
Welcome to the forum
I7pha4t.jpg
 
Hi thanks again for your response I followed your advice and well it started first time but and there’s always a but it wouldn’t Rev up unfortunately plus I noticed the pipes from the inter cooler were flat so I turned it off now The two things I didn’t fit were the air filter box and the fuel filter canister but I fitted a inline fuel filter would that cause the problem thanks much appreciated
 
If it started that is good news, the tdis are great engines.
The flat intercooler pipes say to me you possibly have one end blanked off so it cannot get any air, hence the flat pipes ie it has sucked all the air out of the system collapsing the pipes.
For the test you do not need any of the turbo pipes on, it will rev and run just fine with no turbo pipes on.

Air filter wont make any difference, neither will the inline fuel filter.
So you have either a lack of air or fuel, air mentioned above, fuel could be as simple as a kinked hose, the wrong fuel banjo in the wrong hole in the inj pump, piped up wrong or worst case scenario a duff inj pump.

I have read several threads where the inj pumps have partially seized internally from lack of use, the fuel pin can also seize up ( I have had this myself twice!) have a search here on LZ or google, loads of info out there, if you get stuck come back and someone will help.

Try Bosch VE pump fuel pin seized and see what you get.
 
If you've had the Banjo bolts out of the injector pump be aware that the rear one(fuel return) has a smaller hole in it than the front one (fuel flow). Mix them up and it won't rev.
Where is the return fuel line running to?
 
Well it was a collapse pipe inside so I changed it and everything was fine until it got up to normal temperature and I noticed a little oil drip at the back of the rocker cover gasket were there’s a little half circle in the gasket so I cleaned it off and let it run for a bit longer then I noticed were the head gasket was sticking out there were oil coming from underneath now could it possibly be were the oil had gone underneath and the heat off the cylinder head was pushing it out or something more serious like the head gasket now the head gasket looks newish or the head bolts re torquing down now when it was running there was a bit of smoke but I just thought it was because it hadn’t been ran for ages and it was a temporary set up so I am just wondering what to do next any advice would be very much appreciated thanks
 
Coopers100 said:
Well it was a collapse pipe inside so I changed it and everything was fine until it got up to normal temperature and I noticed a little oil drip at the back of the rocker cover gasket were there’s a little half circle in the gasket so I cleaned it off and let it run for a bit longer then I noticed were the head gasket was sticking out there were oil coming from underneath now could it possibly be were the oil had gone underneath and the heat off the cylinder head was pushing it out or something more serious like the head gasket now the head gasket looks newish or the head bolts re torquing down now when it was running there was a bit of smoke but I just thought it was because it hadn’t been ran for ages and it was a temporary set up so I am just wondering what to do next any advice would be very much appreciated thanks
Click to expand...
You need to find out exactly where the oil is coming from.
If it is from the head gasket, that is not a good sign.
From memory, re-torquing the head is not easy on a Tdi, because the head bolts are tightened by angle, after an initial torque wrench setting.
 
Coopers100 said:
Well it was a collapse pipe inside so I changed it and everything was fine until it got up to normal temperature and I noticed a little oil drip at the back of the rocker cover gasket were there’s a little half circle in the gasket so I cleaned it off and let it run for a bit longer then I noticed were the head gasket was sticking out there were oil coming from underneath now could it possibly be were the oil had gone underneath and the heat off the cylinder head was pushing it out or something more serious like the head gasket now the head gasket looks newish or the head bolts re torquing down now when it was running there was a bit of smoke but I just thought it was because it hadn’t been ran for ages and it was a temporary set up so I am just wondering what to do next any advice would be very much appreciated thanks
Click to expand...

The i/2 circle D shape seals are crap, they need sealalnt applied to them when fitting, use new every time rocker cover is off.
Head gasket is a proper easy job, almost one of the easiest engiens going, only issue you will have is holding the engine still when tightening head bolts.
Head gasket failure on the rear of number 4 cylinder is not unusual on a 200 engine.

Head gasket cheap, Elring good make, new manifold and rocker gaskets and away you go, less than 40quid in parts.

Once in the car with new gaskets and driven a few miles all the smoke will stop.
 
Hi thanks for your responses I have ordered a new rocker cover gasket then I will know definitely were the oil is coming from hopefully the gasket should sort it but I am it usually that lucky but you never know
Anyway could I use a fuel filter housing from a td with 3 outlets on my 200tdi conversion any response much appreciated thanks
 
Coopers100 said:
Hi thanks for your responses I have ordered a new rocker cover gasket then I will know definitely were the oil is coming from hopefully the gasket should sort it but I am it usually that lucky but you never know
Anyway could I use a fuel filter housing from a td with 3 outlets on my 200tdi conversion any response much appreciated thanks
Click to expand...
Assuming that is a CAV filter head you are talking about, you can use it, but you will need to use CAV type filter elements with it.
Delphi are the best elements to get, I don't use any others, and they are fairly cheap.
 
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