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It runs fine, I think the spray pattern was the issue, as upon revving hard, it would almost stall. So decided to just take out all 4 injectors and get them refurbed. I could put the 3 I've taken out back to get it running again, attach leak off pipes etc, but would rather avoid. Is it best...

Hi all, Hope all's well. I have removed 3 fuel injectors and the last one at the back is proving to be a pig, I've used plusgas, heat, slide hammer, it hasn't even moved a mm, maybe 1mm, not sure ha. I will try again tomorrow, but I guess the only way if it's stuck is removing the head and...

Loving the engine! What coating did you use for the timing cover? Just standard powder coating or hand painted, two pack? Mine has some damage and peeling, was thinking of gently shot blasting and powder coating. Ta, James

Ah it didnt upload. I'll add to YouTube and send a link

Hi all, trying to get to the bottom of this issue. Here's a video. Noticed it recently, upon revving hard, the engine nearly cuts out, never has done, just splutters for a second. It may have always done it, I just noticed it when I revved hard to check for a turbo whistle. Which is now sorted...

Pipes seem fine. Slight leak on one. However, I've just noticed one of the flange bolts on the timing belt cover has featured and there's a bit of a leak. I'll remove the fan and replace the bolts and get a better look at the pipes while I'm in there.

Hi All, Further to my recent posts, on a bit of a fault finding mission. 1992 200tdi, runs fine, but recently upon revving - relatively hard - when stationary, the engine stumbles, doesn't stall, just judders for a second, then carries on idling. Drives fine, as in gear changes are ok, I just...

I guess the only likely reason is it's cross threaded somehow? I didn't put it in, so must have been the previous owner. The LT77 oil drain plug also has a crack originating from there and shooting up the casement, so I guess I'm cleaning up after a heavy handed previous owner who liked to over...

No Joy, heat, lubricant, anti seize plusgas, tapping, spanners, crows foot spanners, she's not budging. Never had such grief removing before. Time to remove the injection pump. Thanks all.

No joy here, tried loosening the thread overnight and weekend with plusgas and wd40 anti thread penetrative spray, whacking it about a bit and a crows foot spanner filed down. Not touching anywhere when trying to undo and still a pig to get out. Has anyone else had such issues removing? I will...

I've got a replacement solenoid - FLAG germany and also a genuine Bosch, gonna use the bosch once the bugger is loose. So everything new. I was going to take the pump out, but just thought it would be a quick enough fix, even with the awkward position.

She didn't budge, so I'll do just that. Thanks.

Thanks all, think I'm gonna have to buy a crows foot spanner, I have fashioned a spanner that will get in the area, without hitting the pump body, but the solenoid itself is super tight, I worry if there's corrosion on the thread, which would mean moisture, which would mean, bad! Though it may...

Thanks for the reply..spanner is no issue, just can't get the damn thing to turn, whoever designed it didn't really think overly hard. If I grind anymore off the spanner itll be too weak to loosen. I'll have a coffee and try again.

Trying to remove the damn fuel stop solenoid from the injection pump, fashioned all manner of spanners, no joy. Any ideas to help remove. Stupid question, but it's definitely a normal thread? Lefty loosey righty righty? Thanks all

Brilliant article, thanks!

High mileage and compression issues yes, thanks

Hi All, hope all's well. I want to get someone reliable to completely rebuild my 200TDI. I would do myself, but would take me an age and I don't have the time due to work commitments home and away. I am based in Berkshire, if anyone can point me int he right direction, great. TIA

Thought they'd be somewhat a rarity. Not sure if they are or not, previous owner said they were, wouldn't surprise me. I've seen a few ally ones, so I'll give it a go.