200tdi injection adjustment - Defender Source
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  #1  
Old May 7th, 2011, 07:47 PM
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Robert Courtney
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200tdi injection adjustment

My 200 is getting horrible milage and smokes under heavy acceleration. Is this an easy fix by turning down the pump?
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  #2  
Old May 7th, 2011, 08:19 PM
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John B.
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It is doubtful that the problem is too much fueling.

Check timing.

Check injectors.

Check compression.

Is turbo coming on boost?
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  #3  
Old May 7th, 2011, 11:06 PM
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Check the easiest thing first, intake or exhaust restrictions.
Is this all of a sudden or gradual worsening?
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  #4  
Old May 7th, 2011, 11:50 PM
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Depending on the age of the injector pump (IP), it could also be the large spring under the diaphram (large mushroom shaped cap on top of the IP). The spring weakens with age and this allows too much fuel to go to the injectors before the turbo boost is up high enough to provide more air for the burning of the fuel. This leads to high EGT's and can distroy a turbo in short order. Do a search on Bosche VE injection pumps to get all the details (often written about in Dodge Cummins sites as they have the VE pumps too). Guys often modify the spring setting to get higher performance (more fuel at lower RPM's before the turbo boost kicks in).

If it is this problem, turn the large knurled nut (it's more like a wheel) inside a full turn to INSREASE the spring tension (there's a device in there that keeps tension on the knurled wheel. Looking down into the chamber where the spring is, you'll want to turn the wheel, I beleive counter-clockwise, to bring the wheel up towards you to increase the tension on the spring. But BEFORE you ever pull the diaphram out, mark the diapham in relationship to the pump housing BEFORE you pull the black rubberized canvas diaphram out. It needs to go back together in the same place. There is a eccentric cone attached to it that can also change the fueling amount by rotating the diaphram in relationship to the IP housing.
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  #5  
Old May 8th, 2011, 09:34 AM
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Robert Courtney
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It is a newly rebuilt engine and a brand new injector pump. I got it from Duncan Goodchild and he mentioned he tuned the engine up 25% whatever that means.
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  #6  
Old May 8th, 2011, 10:10 AM
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might seem obvious but I would try to talk to Duncan and ask what exactly he did so that you can have a baseline for further adjustment.

Quote:
Originally Posted by bcourtney View Post
It is a newly rebuilt engine and a brand new injector pump. I got it from Duncan Goodchild and he mentioned he tuned the engine up 25% whatever that means.
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  #7  
Old May 8th, 2011, 05:41 PM
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Robert Courtney
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Actually I have just haven't heard back yet.
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  #8  
Old May 8th, 2011, 06:47 PM
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What is "horrible" mileage?

Can you hear the turbo?
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  #9  
Old May 8th, 2011, 09:25 PM
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Robert Courtney
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Yes turbo is working fine, maybe 16 mpg.
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Old May 8th, 2011, 11:05 PM
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Are you measuring distance and fuel accurately?

How is power? How fast can you go?
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  #11  
Old May 9th, 2011, 06:34 AM
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Robert Courtney
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Quote:
Originally Posted by Red90 View Post
Are you measuring distance and fuel accurately?

How is power? How fast can you go?
Yes on my calculations.

Power is great, with my gearing and the LT230 I can easily go 75 which obviously is a thrill in an SIII.

What about break in is that a factor in initial economy?
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  #12  
Old May 9th, 2011, 09:08 AM
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If it is "just" fueling, the answer is in your right foot. How fast are you normally driving? What is the rest of the drivetrain, so we understand the gearing?

How much smoke? Is it only at full throttle? If it is smoking hard and there is nothing else wrong, then your EGTs will be dangerously high.

Really, there is very little to look at on the engine, these are very simple engines. Check timing, check injector spray pattern. Make sure the intake is not plugged.
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  #13  
Old May 9th, 2011, 03:25 PM
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Robert Courtney
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LT77 / LT230 / 3:54 gears 33's

Just smokes black under hard acceleration fine otherwise.
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  #14  
Old May 9th, 2011, 03:30 PM
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what is the LT230 ratio?
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  #15  
Old May 9th, 2011, 03:37 PM
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For a baseline ive got a 110 as well:

110 truck cab
200tdi
lt230 1.6
LT77 5speed
235/85-16

I romp on the truck and get anywhere from 23-26 mpg per tank 90 miles a day round tip to work through the worst north NJ traffic
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  #16  
Old May 9th, 2011, 04:44 PM
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Following you around that one day in Saratoga, I'd say you drive it pretty hard Court.
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  #17  
Old May 9th, 2011, 05:43 PM
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Driven exuberantly they get crap for mpg-in my case/experience. You learn to drive them differently than you would a gas engine. Took me a while and a lot of tanks @ 17-18mpg.
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  #18  
Old May 9th, 2011, 06:01 PM
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If you do have your foot to the floor a lot, then turning down the fueling will help.... Or you could just ease off. If it is smoking, you are tossing fuel out the exhaust.

It is amazing what different driving techniques do. I keep track of mileage on all my cars. My son and wife get a solid 30% worse economy on our diesel VWs than I do. I really have no idea how they manage to do it, but it is a fact.
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  #19  
Old May 9th, 2011, 06:22 PM
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Robert Courtney
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All good points, considering I have a Silverado that they claim gets up to 20 MPG and I never get better than 13. I will try a more relaxed foot and report back.
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