2003 200 HPDI bogging

[noleman17]

I have a 2003 200 HPDI that was blowing the fuse that works the ecu, fuel pump and ignition coil. I took off most of the ECU related components cleaned them and their connections, and inspected the wiring(I didn't find any frayed wires). I also fixed a slightly kinked spot in my fuel line and put a new fuel filter/water separator on. it has stopped blowing fuses but i took it out Friday and it was bogging down a little bit at varying RPMs and got a lil better as the day went on. I took it out Saturday and it was bogging down so bad it would not go above 1000 RPMs and would die if you gave it too much gas. It idles fine and it will rev a lil bit in neutral but still does not run right even then. any ideas what could be the problem?

[noleman17]

I have replaced the water separator fuel filer, the filter in the clear canister, silver filter feeding the high pressure pump, spark plugs, and i cleaned the vst filter and the filter behind the pressure regulator with a sonic cleaner. Did not fix it. I took it to a mechanic he says I'm running on 2 cylinders, when you unplug the injectors on the right side and the top one on the left side there is no change. The mid range fuel pressure is 50 but very quickly goes to 0 when the motor is switched off, is that normal? the mechanic admitted he didn't know and would be throwing parts at it and said he would start with the pressure regulator. could that be the problem? and are there any more tests i should run?

[noleman17]

also the cap for my diagnostic plug was left off and corroded to the point one of the prongs is gone. THANKS previous owner! Is there any way to set the TPS with out the computer? And can you check the high pressure fuel pressure with out a computer? Please help!

[coueytwo]

what is the model number of your motor?

[noleman17]

Z200txrb i think. Its at the mechanics shop now. I know it says jan 03 on it.

[rodbolt17]

every sensor on the motor can be set with a digital meter a service manual and test harness's.
in a pinch paper clips slipped up the backside of the connector and jumper leads can replace the test harness.

all the tests and voltage specs are in the service manual.

myself I would go find any blown EFI fourstroke or any Z,VZ,or LZ motor and cut off the connector and splice it on your harness.

[noleman17]

Thanks i have ordered a service manual and i am trying to find a harness with a good diagnostic plug.

[mrpontoon]

just buy a new plug
/www.easternbeaver.com/Main/Elec__Products/Connectors/Sealed/SMHW/smhw.html