Vehicle & Technical > Defender

2.5 TD running rough after re-build

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Graham2:
Evening all, I've just put new rings, big end shells etc in a 2.5 turbo diesel 110 Hi Cap. I bought it cheap, to do up in lunchtimes at work. It ran OK but was breathing heavily, so I thought new rings etc would help. I know I should put a 200 tdi in it, but the idea is to run it for a while, then put a 3.9 V8 on gas in it. No point going tdi anyway, as in 2 years Red Ken will charge me £200 per day to drive it out of the garage!!! The head went back on well, with recon injectors, new glow plugs etc. It started second turn of the key, but runs very badly, rather like a petrol 4 cylinder with 2 leads on the wrong plugs. Fuel system was bled, but it won't rev and I get a huge cloud of white smoke (un-burnt fuel?) from the exhaust. Valve clearances are OK and both steel and copper washers are on the injectors. The fuel pump has not been touched during the top end re-build, but could this be the problem anyway? Would the extra compression from the new rings and re-ground valves be causing it? I thought I was doing the engine a favour. Any ideas anyone?

ian_s:
i know i might be a tad cynical, but you say you put recon injectors in, do you still have the old injectors?
my first thought was your injectors not atomizing the diesel properly, then i re read what you wrote, and that stuck out like a sore thumb!
i always question the 'new' parts i fit if something isnt working like it should.
do you still have the old injectors? if so, refit them and see what happens

Graham2:
Thanks for the reply, but I re-fitted the old injectors, and it was still the same. When I try to put my foot down to move the thing back into the garage, it has very little power, and chucks out tons of white smoke. If I loosen an injector nut to try and bleed any air out, the engine stalls, which it didn't do before the re-build.  Maybe I should mark the fuel pump, and try adjusting it to see if it makes any difference. If it does, it would suggest the fuel pump timing is out, but I haven't altered it?! Is this the only thing worth trying? I don't really want to pull the head off again...

LeanneNCharlie:
hi. another possibly silly question but its worth a stab at. did you put the push rods back in in the same order they were removed? or fit new ones? did you reset the tappets when you put the head back on? only asking because when i rebuilt my 300tdi head i didn't reset them,(silly i know!) just put them in and away we went. it was very very sluggish and took some effort to start. turned out the exhaust valves were not closing fully so loosing compression. reset the tappets and it flies now, as much as a diesel will anyway!

even after rebuilding our 90's td engine it still smokes 40 a day when cold. so add this to valve clearance and it could be similar to what you are suffering.
set the clearances to 0.2mm for both inlet and exhaust.

hope this is of help.

charlie.

Graham2:
Tappets are set OK, double checked them. I've tried turning the fuel pump a bit, and it's made it a fraction better. It ticks over a bit better, not jumping about so much, but still produces its own cloud when revved. I can only put it down to the timing belt slipping on a sprocket, meaning the fuel's being squirted in at the wrong time, causing the un-burnt diesel to come out as white smoke. I've ordered a new belt, but the nut on the end of the crank doesn't want to come off. I think a 3 foot length of scaffold tube is the answer!

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