There shouldn't be anything holding it in,mine came straight out. If your not sure dont force it and just adjust the diaphragm without taking it out and leave the star wheel alone.
 
Sounds like good advice v8jon, thats what I desided to do. Put 60 degrees cw on diaphragm, seams to be the best with 2 turns on the smoke screw. At 90 degrees on diaphragm its quicker but smokes to much, and at 120 it smokes less but starts to return to normal power. I also tried 6o degrees ccw, boy it slowed down to the point I thaught "what have I done"!

I wonder what can be holding the diaphragm in mine, has nobody else had this problem? It definately comes to a metalic solid stop, and I am not brave enough to force it beyond this point... thanks for the tips.
 
Bit of an oddball question but i'll ask anyway- I suspect my 300TDi Disco has been tweaked but i'm not sure how much....it has the straight pipe, full width Allisport intercooler and Allisport hybrid turbo already. How would I know everythings been adjusted already and can I turn up the wick a little more than a standard 300?

Does smoke a little on normal driving (black smoke) which leads me to think the fuellings been done but not boost- will be fitting a boost guage next weekend.
 
Just tweeked my pump 90 deg on diaphragm and 1 1/2 turns on smoke screw. Wow what a difference. Too much black smoke though so turned the diaphragm back to just 45 deg from original setting and 1 turn on the smoke screw. It's now too dark to test but I'm hoping all is good when I test it tomorrow. I can't believe the increase in performance from just playing with such simple tweeks.
 
It's surprising how much of a difference it makes,I did mine about 18 months ago and ive done around 10'000 miles in it since and it's still going strong.
 
I know, I'm trying to sort one for a customer at the moment either way will be expensive if you have to pay someone!

I don't really think the gains justify the costs - as they arn't like the modern day chips with turbo diesels :(
 
I don't really think the gains justify the costs - as they arn't like the modern day chips with turbo diesels :(

That's why I've been looking at changing his pump. But that'll be darned expensive too!!!! All right if you're doing it yourself.
He tows a lot, most weekends, should've got a manual really but he likes it!
 
Just did the mod on my 200 tdi disco.
did the torx 1 1/2 turns
star wheel 1/2 turn
diaphragm 1/2 turn

Little bit of smoke but not too bad. Certainly more oomph on the pull away.. :D

When I took the cover off, there was a load of black oil in there which looked liked it came from the pipe going to the turbo.. Anyone got any ideas on that..?
 

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