pulled the injectors and they are pretty nasty at the tips with carbon buildup. took them apart and soaked all the parts in cleaner and blasted compressed air thru the jet holes......reinstalled and no difference on smoke amount out the exhaust
 
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.
yes used the pin and according to the pulley markings. Its at TDC and the slot in the flywheel was visible..not an automatic trans.. i have not pulled the front cover off at this point.
 
pulled the injectors and they are pretty nasty at the tips with carbon buildup. took them apart and soaked all the parts in cleaner and blasted compressed air thru the jet holes......reinstalled and no difference on smoke amount out the exhaust
If they are knackered, cleaning isn't going to sort them out.
You need to get spray form and opening pressure tested.
 
How are the other 200tdi injectors?

If sending away for proper rebuild send to Diesel Bob, he/they know what they're doing. Or, just buy a new Bosch set and be done with. It save a mass of p!ss!ng about.

 
Better to loosen off the unions one by one, as I suggested.
That way, if one cylinder makes no difference, you know that is the problem injector.
And if none of them make a difference, you know it is something else.
did that before i removed and cleaned them...i am getting fuel spray at that union and when each union was loosened.... the engine idle changed slightly...all were similar, and each did the same thing when loosened
 
How are the other 200tdi injectors?

If sending away for proper rebuild send to Diesel Bob, he/they know what they're doing. Or, just buy a new Bosch set and be done with. It save a mass of p!ss!ng about.

they other injectors seemed decent..i did have some smoke on heavy acceleration on the other motor but that may have been a result of several factors
 
How are the other 200tdi injectors?

If sending away for proper rebuild send to Diesel Bob, he/they know what they're doing. Or, just buy a new Bosch set and be done with. It save a mass of p!ss!ng about.

You can buy pop testers off the net, think they start from about 50 quid.
 
compression check is next list and air cleaner is clean..also tried with air cleaner removed. n engine fires right up and idels but a little rough and black smoke with any acceleration.... timing issue?
Has it got one of them stupid tuning fuel pins in the injector pump?
They cause the engine to black smoke pretty much through the entire rpm range.

Are the plastic or metal seals still on the two M6 lock/stop bolts on the injector pump throttle linkage?
 
compression check is next list and air cleaner is clean..also tried with air cleaner removed. n engine fires right up and idels but a little rough and black smoke with any acceleration.... timing issue?

that’s interesting should try driving it and see what power is like
in front of the seals is the boost pipe connector to turbo , I’ve removed mine as I’ve fitted a DI, but if that was holed could affect power, also there is a lifting needle in pump that I’ve read sometimes seizes , ( stupid tuning fuel pin?) . There is also the 200tdi tuning guide which is a good read and might show it better



E876AF56-3D80-45B4-927D-B2F439572768.jpeg
 
You tried Italian tune up?

I don't think that's the answer unless OP knows everything else is good. If good he should be running a system cleaner and then try the Italian service.

@mikeNC, I like @lynall suggestion re' FiP fuel pins. Many folk are tempted by these yet most just bellow out black smoke + if an ex-Arkonic engine there's a good chance they've fiddled with something for bling mode.

The other point we've all yet to ask is, why did Arkonic sell this engine and what was the build spec...especially any modifications? If they've added sporty mods and were unable to run the engine without black smoke the engine should be taken back to standard, set up and be proven to be a good engine running without black smoke except the std 200tdi puff at start up.
 
that’s interesting should try driving it and see what power is like
in front of the seals is the boost pipe connector to turbo , I’ve removed mine as I’ve fitted a DI, but if that was holed could affect power, also there is a lifting needle in pump that I’ve read sometimes seizes , ( stupid tuning fuel pin?) . There is also the 200tdi tuning guide which is a good read and might show it better



View attachment 288750
Hells teeth man that inj pump still has the factory seals on it!
 
I don't think that's the answer unless OP knows everything else is good. If good he should be running a system cleaner and then try the Italian service.

@mikeNC, I like @lynall suggestion re' FiP fuel pins. Many folk are tempted by these yet most just bellow out black smoke + if an ex-Arkonic engine there's a good chance they've fiddled with something for bling mode.

The other point we've all yet to ask is, why did Arkonic sell this engine and what was the build spec...especially any modifications? If they've added sporty mods and were unable to run the engine without black smoke the engine should be taken back to standard, set up and be proven to be a good engine running without black smoke except the std 200tdi puff at start up.
Engines like being fully warmed up. The behaviour of an engine that has just been started and run on idle is often quite different to one that has had a good run out.
I can't see it doing much harm as long as the injectors are spraying, not producing solid jets of fuel, and the turbo isn't putting oil down the inlet tract.

I too am interested in the origins of the engine.
I have no idea what Arkonic is, but the idea of an engine that hasn't been made for nearly 30 years being removed from a vehicle, having only run 3k miles, and then sitting for two years on a garage floor, before being sold to this "lucky" buyer seems full of inconsistencies.
 

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