I have a 2001 P38A 2.5D and had a fuel leak on the timing chain side of the injector pump. Not being very knowlegable about these things I booked it in to a local fuel injection specialist repair garage and there had the pump removed and had all the seals and gaskets replaced. I picked the car up a few days later but then found that even when I drove the car like a vicar on a Sunday afternoon I could not get more than 20mpg when before I took it in I could get 26+ driving it in the same manner, I was originally getting 17-19mpg towing a 1500kg caravan. The car has now been back another two times and they have reset the timing and replaced a couple of small diameter rubber pipes- I couldn't tell you where they go to- but it has made no difference. Both the garage and myself are at a loss of what has gone wrong PLEASE can help before I loose it completely as I cannot afford to run the car and tow a caravan with these mpg figures. Thanks. :confused2:

Sounds like it is grossly overfuelling....you have to set the pump timing correctly using a dti gauge as the measurements for setting the pump are in the thousandths of an inch!

Are they a Bosch specialist or just a diesel specialist...may pay to find a Bosch specialist...

They are Bosch, Delphi and Denso specialists so I can only assume that they know what they are doing. The quote from their website says as follows:-
"Trained Technicians Bosch, Delphi & Denso,Bosch KTS,Denso DST,Delphi Diamond,Fault Code reading Auto Electrical."

The little pipes were probably the leak off pipes. All the gaskets must have been pretty bad to require taking the whole pump off.

If it was overfuelling that much wouldn't the revs be too high? Should be 750 rpm at tickover (warm engine).

If you can get a printout of what the parameters are at tickover then maybe some of the diesel gurus would understand it.

It starts first time and ticks over at about 700-800 rpm but sounds sweet, its weird.

Wammers is the oil burning guru....

Fuel quantity solenoid maybe?? Clutching at straws with that, and Wammers will no doubt shoot me down in flames....

Well, if we're clutching at straws and in the absence of anyone who knows what they're talking about ...

How about a temperature sensor? If one of them was disconnected / damaged would it think it was cold all the time and shove too much fuel through?

Fuel temp sender is a good shout, would need to go on diag for pump readings. If pump has been stripped fully should have been put on calibration machine on reassembly.