got my engine in but it wont rev past 2000rpm

[Ace]

Well my engine, after much stuffing around and trips to bruce davis to get stuff i forgot etc etc the engine is in and running, it fired first go, but it wont rev past 2000rpm. I have bled the fuel system and cant get anymore air out of that, i losened each injector and let a bit spray out as per Bruce's suggestion, i put compressed air into the tank as per another suggestion and nothing.

So what else could it be. It idles perfectly and revs well but if you hold your foot flat to the floor it tops out at just over 2000 and then when you let your foot off the throttle the motor nearly stalls and then it comes back to life with a bit of a shudder. Any suggestions?

[justinc]

Well my engine, after much stuffing around and trips to bruce davis to get stuff i forgot etc etc the engine is in and running, it fired first go, but it wont rev past 2000rpm. I have bled the fuel system and cant get anymore air out of that, i losened each injector and let a bit spray out as per Bruce's suggestion, i put compressed air into the tank as per another suggestion and nothing.

So what else could it be. It idles perfectly and revs well but if you hold your foot flat to the floor it tops out at just over 2000 and then when you let your foot off the throttle the motor nearly stalls and then it comes back to life with a bit of a shudder. Any suggestions?

ACE, I reckon 1 of two things, the Lift pump is connected up back to front, IE inlet and outlet mixed up, or the wrong banjo bolts are on the injector pump connections. The 13mm socket sized one goes on the inlet up the front of the pump, and the 17mm size one goes at the rear of the pump. (This one actually has 'out' written on it as it has a restrictor in it.

JC

[Ace]

ACE, I reckon 1 of two things, the Lift pump is connected up back to front, IE inlet and outlet mixed up, or the wrong banjo bolts are on the injector pump connections. The 13mm socket sized one goes on the inlet up the front of the pump, and the 17mm size one goes at the rear of the pump. (This one actually has 'out' written on it as it has a restrictor in it.

JC

Hi JC, i think you might be onto something with your second one, the 13mm one is on the rear, and the larger one is hooked up to the hose closer to the front of the pump. I will swap them around in the morning and report back.

Its not the lift pump cause i have replaced it twice before working out it was that the fuel line was to short, so i know which one the new line goes on. Matt

[camel_landy]

Check the condition of the turbo boost compensating mechanism on top of the fuel pump. Also, have a check to see that it's getting the feed from the turbo properly.

Another one to look at is the position of the throttle linkage where it's connected to the injector pump. Try it 1 notch each way & see if that makes a difference.

Either way, it sounds more like a fueling issue.

HTH

M

[justinc]

Hi JC, i think you might be onto something with your second one, the 13mm one is on the rear, and the larger one is hooked up to the hose closer to the front of the pump. I will swap them around in the morning and report back.

Its not the lift pump cause i have replaced it twice before working out it was that the fuel line was to short, so i know which one the new line goes on. Matt

Matt, those are the wrong way round. The inlet one you have hooked up is actually the return banjo bolt, and has a restrictor. It'll be the problem for sure:)

(Don't ask me how I know this...:( I've been working on these engines for a long time, so at some time or another I have probably made these little 'discoveries' :(:))

JC

[feraldisco]

are we talking Td5 here?

sounds similar to my problem - motor smooth but hard to rev past 2500rpm, air supply is fine, electrics should be fine (new loom and ECU), turbo fine, so am thinking it must be a fuel feed problem...

[foz.in.oz]

- No.

[spudboy]

Justin sounds like he probably has the answer, but if that all checks out try feeding fuel into the engine bay from a container directly (i.e. take the fuel tank out of the equation).

I replaced a fuel tank on a 300TDi and had similar symptoms of starting OK and idling and reving up to 1500RPM OK, but no power and no revs over 1500.

It was the plastic clip into the fuel tank which was letting in air into the line in small quantities.

We rigged up a jar of diesel straight to the engine and it went 100% so eventually figured out it was the fuel tank connection. Took best part of 2 days to nut that one out :(