High RPM Power Loss/Stuttering/Stammering 200 Tdi

[matthamilton]

At a complete loss as to what to try next. Truck starts and runs without smoke and runs at low rpm’s like it was new. Thought I had bad fuel. Replaced racor filter, drained bowl, and fuel and again at high rpm’s after about 10 minutes of driving the engine begins to lose top end power and then starts to stutter and run rough. Engine never dies.

Replaced the lift pump since they are crap. No change. Then I replaced the fuel lines with braided hose and AN fittings. Nothing changed. Had injectors and injection pump rebuilt. Nothing changed.

Going to do a compression test and depending on results I’ll then do a leak down test.

Oh, also removed fuel cap to make sure tank was venting properly. No change.


Any ideas forum gentlemen? Has anyone ever had this before???

[Red90]

Did you pull the pickup from the tank and verify it is clear?

Have you inspected the intake for collapsing hoses?

[matthamilton]

Did you pull the pickup from the tank and verify it is clear?

Have you inspected the intake for collapsing hoses?

Fuel sender is also new and when I replaced it I pulled the tank, drained it and filtered the fuel through a paint filter and found no impurities. Also no water.

[DazzaTD5]

To me this sounds like a fuel starvation issue.
I cant think why anyone would recommend overhauling the injector pump and injectors based on the info you have provided.
My 200tdi had a leaking very badly injector pump and it still pulled like a little thomas tank engine.

My first obvious thought was a blocked or partially blocked fuel tank pickup or the dam lift pump.

*if you stop and turn it off then start again is it fine for a bit? or is it still rough runing?
*if it is still rough running, turn off, dis-connect the fuel line from the tank but in the engine bay, the 200tdi filter is on the firewall is it not? (cant remember) and blow down the fuel line.
*Also look for a squishy soft part of the fuel line or a kink in the line, or anywhere it might be getting squashed between the body somewhere.

P.S failing all that, email Mike (Britannica Restorations) he is the man for old Defender everything. (search Youtube)