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Ahh well goes to show the only TD pumps i've examined have the 2nd electrical connection!

For cold starting timing must be ADVANCED. That is why we power the solonoid during cranking. (very basic system) It overrides the automatic system. At idle timing is then at a base figure, then it advances *automatically* as revs and load rise. This is a function of case pressure and the...

Stop solonoid is the top one points vertical between the injector feed pipes. The other sits at the bottom of the pump horizontally. Can we get some photos, please!!

A TD pump with TDI injectors on factory settings should still give somewhere around 100hp, assuming the rest of the thing is working as its maker intended. Handily, you can turn them up. :)) <however get it running properly FIRST> Stop solonoid needs to be connected to a switched live, via a...

Is it possible you can get some photos on here as to where the Mech Inj Pump has been coupled up to electrically? Obviously the stop solonoid isnt connected to where it ought to be!! Goodness knows if the advance sol. is connected to anything??? Rev counter could be trickier, depends on your...

Rev counter is driven from either the timing case or the TDI pump itself on the Zexel trucks. Although check on the bell housing by the dipstick ... No rev / white smoke problem is either : Inj. pump is not able to suck pure fuel due to restriction / mini filter / sucking air. Lift pump within...

It'd possibly alot cheaper to get it running properly on the TD pump than taking it back to the fly-by-wire, in your case a zexel pump. Where are we at with the symptoms ?

Can you take some photo's please so we know *exactly* what we're dealing with ? From all those codes "open circuit" especially relating to pump and pedel etc does sound like a TD pump conversion...

The pump must be operating at the correct case pressure for the advance system to work properly. Any air or cavitataion and it wont. You'll see the adv sol figures going haywire and also likely the truck will splutter, emit clouds of white smoke and be unwilling to rev over 3000rpm. Which leads...

What happens if you cycle the ignition? Does that restore it? Is the Limp mode triggerable at will under certain conditions ?

Tuning Box does the trick, proper remap yields much more. (best results on bosch system)

Surprised no one has said "mini filter" yet.....

The MAF housings are indeed the same, as is the bolt pattern and the air filter lid between the TD and ZD . The MAF elements are NOT the same. The ZD has the much better flowing plastic airfilter housing which can be retro-fitted to the TD if you dont fancy butchering your own.

And the Manual gearbox uses regular engine oil ! ( 5w-30 ) Change interval - 40k. Tim..

I've just double checked on this... The Xtrail indeed uses an open diff, however there is a multiplate wet clutch pack in there too which brings in the 4wheel drive when the ECU commands it. For that reason I would use EP90LS. (600ml) The transfer case uses regular 75w-80 gear oil (500ml)

Xtrails have an open rear diff.

£330 f/comp, max no claims, with business use, NFU.

The 3.0 16v 4jx1 is the nightmare motor. Avoid at all costs! The catepillar 'pumpe duse' type unit injector set up is an incredibly good system, just the execution of it was beyond words in this application! The 3.0 4jj1 is the current offereing in the Rodeo etc and is fine.

2.8 nozzles fit the stock TDi small injectors and are larger :>

At 50-60mph the engine is likely turning at rpms where it produces max torque. This is the point where the clutch is under the most strain to transmit without slipping. Are you running stock power ? If standard then you've got problems as the standard clutch is normally happy to 160hp at...