LPG system not working. I've made it worse!

[KarlT]

Long old story so bear with me.
Bought Doka with LPG system fitted to the 2.1 engine.
Worked perfectly. Only thing, LED tank gauge didn't work. Never knew how much gas I had, but it didn't bother me.
Engine blew rubber head gaskets.
Removed engine, fitted new gaskets, re-fitted engine.
Also when engine was out, I washed down the tank & locker area. Don't think valve got wet as I covered it with plastic bag.
Now the problems begin...........
Engine runs fine (if alittle rich) on petrol
Switch to LPG & all was fine as long as the revs were kept up. As soon as the revs dropped below 2000rpm it would switch back to petrol. Although strangely only after the first 400 meters.
I drove about 70miles like this, mostly motorway, so not too annoying & mostly on gas.
Was told it was probably the coil pickup or bad connection.
Today I went through all the connections that may of been disturbed during engine refit.
Looking at them, none looked dodgy but remade most, I don't think its these.
I also had a mess around with the valve on the main tank..............

I tightened the valve covers, top left & the bottom one, as they were loose.
Looked at the wiring to the solinods but seemed okay.

Now diaster............Starts & runs great on petrol, but as soon as I switch to gas, engine stalls, not getting any gas.
While I was out, called in to garage to try refill. I can not put any LPG into tank, Pump was acting like tank was full but I know this cant be possible as I drove 70 miles on it.
Sorry for long story but wanted to spell out what has happened & history. Also last week battery light stopped working, don't think this can be connected but thought I'd mention it.

[steve8090]

Fool boy, did you not read my reply, they are not covers but valves, they will need to be open, ie turned all the way anti clockwise and the fact its in a space or void like the locker does not exempt it from being vented properly, I really don't want to say I told you so.

[72BUG]

Don't really know much about LPG systems but when you say you've tightened the valve covers are you sure you haven't inadvertantly shut off the valves. It just sounds suspicious that there are 2 "valve covers". In and out? and you're not getting fuel into or out of the tank.

Never mind. Just seen Steve's reply.

[KarlT]

There is another 3 hours wasted!!!
I must of read your reply wrong. Is that why I cant fill tank up now? What do they do?

[KarlT]

In my messing & frustration I also turned this little black valve thing.....on the right next to the solenoid. Its on the pre-heat thing. I know my LPG, don't I?
Is it setting important?

What does it do?

[AngeloEvs]

You shouldn't adjust anything TBH if you are not sure of what the various adjustments do. That looks like the Diaphragm adjustment to me. I could be wrong but if it is then it shouldn't be altered as it controls the sensitivity of the diaphragm. How much did you alter it by? Can't you take the van to a local LPG specialist, get it sorted once and for all.

[KarlT]

I know but I can't help it!!
Loads but good news is I took this photo before hand. Should get it roughly in same place from that!!
Will give it all ago tonight.

[KarlT]

Okay, Its back to working fine at high revs, but as soon as the revs drop below, say 2000rpm. It wants to switch back to petrol, sometime stalls. I've checked all the cable joins, What else could it be?
Could it be the engine timing/tappets being slightly different after engine re-build?
May have to go to a specialist, Any good ones in Torbay area or a LPG approved list?

[AngeloEvs]

If its running fine on petrol it should also run just as well on LPG if the gas is set up correctly and there are no issues with the wiring/connections. It could be something really simple that has been disturbed when you refitted the lump. Apart from wiring did you remove any of the LPG components? If the engine stalls then the gas will automatically switch off. May be the lpg mixture is just too weak at low rpm, or the petrol manual shut off control solenoid is in the wrong position, diaphragm sensitivity too tight, etc. There are so many possiblities and its hard to diagnose and give useful advice given that the system has been disturbed.

Do a search on google, heres one where you click your location on the map.......................

http://www.drivelpg.co.uk/AI/index.php

[wasserleaker]

Looks a well dodgy installation , the filler and feed pipes and entire valve area on the tank should be vented to the outside of the van if the tank is in the van, so any leaks dont fill the van with gas.

[Ian Hulley]

the filler and feed pipes and entire valve area on the tank should be vented to the outside of the van if the tank is in the van, so any leaks dont fill the van with gas.

I believe from previous posts that this is in the external 'dead man's' locker on a DoKa

Ian.

[steve8090]

Even so it is still an enclosed area and the owner has been informed that this installation contravenes the specification for UK lpg conversion, in the event of an accident or other matter involving the insurance they will not pay and in fact if they inspect it they will void his insurance, he has been told it up to him to stop fiddling wit the system and get it sorted out properly before somebodies life is in danger.

[CovKid]

Have to agree with Steve here even if I do support DIY installations where they meet COPII etc. If you don't know what you're doing and the existing system clearly isn't up to modern standards, better to get it checked/repaired by a recognised installer.