2.1 DJ Component Testing - Bristol ( or otherwise )

[Smiffo]

Morning all.

I think I now have all the required components to instal the DigiJet onto my DG engine.
The parts have been acquired over time, but not many of which are from known good vans.

What I am looking for is someone with either a local working example to put my bits on and see which are good, or perhaps someone with a test rig I could have my bits tested with them? ( Happy to pay for time either way )

What I am thinking is instal the items I have one at a time, and see if all good - recording which are good and not.

I am trying to avoid taking a working van off the road, make all the changes to loom and cooling system etc, then find it doesn't run correctly or at all. Knowing the working condition of the below would help, and I am willing to pay for the time taken to establish that before I start the work:

AFM ( x2 to try )
ECU ( x2 to try )
Idle control Unit ( x2 to try )
Idle control valve ( x2 to try )
Throttle body ( x2 but pretty sure one is duff anyway )


Aside from that I have a DJ bleed rail, loom, plenum, seals, throttle cable, 2nd temp sensor, and DJ cooling hoses, so I think I am ready if the above components are known good 



 

[maxstu]

Hi Steve,

First, I would install all cooling components (oil cooler, thermostat etc?) where possible without compromising the DG set up, and temporarily block temp 2 sensor.

All the DJ components can be pre-tested according to Bentley. But somewhere along the line it is going to be a suck it and see test.

T'were l closer.

Regards
Stuart

[maxstu]

Wiring core condition is most important, too . So being handy with a multimeter is paramount.

[maxstu]

Wiring core condition is most important, too . So being handy with a multimeter is paramount.
Test all the loom in the comfort of your house beforehand.

[Smiffo]

Hi Steve,

First, I would install all cooling components (oil cooler, thermostat etc?) where possible without compromising the DG set up, and temporarily block temp 2 sensor.

All the DJ components can be pre-tested according to Bentley. But somewhere along the line it is going to be a suck it and see test.

T'were l closer.

Regards
Stuart

Yep. I was going to skip oil cooler for now.
Instal new bleed rail with extra port blocked off, and instal temp 2 sensor with no wiring connected.

That's all I can do cooling wise, without deleting the Pierburg choke ( which is operated by coolant loop through it. )

I did read testing docs, but as you say, the ECU, and I think AFM are going to be my weakest links.

Good point on loom too in other comment. They must be crusty now 

 

[maxstu]

DJ engines love quality earth wires.
Unless you have special equipment, testing parts such as fuel pressure regulator, pump and injectors will be "on vehicle" testing.
Also vacuum plays a important role too. Have you a DJ dissy?
And what about replacement fuel tank?

[Smiffo]

DJ engines love quality earth wires.
Unless you have special equipment, testing parts such as fuel pressure regulator, pump and injectors will be "on vehicle" testing.
Also vacuum plays a important role too. Have you a DJ dissy?
And what about replacement fuel tank?

I have the dissy ( only one of ) and darn it.... The fuel tank....
I had forgotten about that.

I have the pump, fuel lines and everything - except the damn tank 

[maxstu]

Source a DJ/SS/MV injection wiring diagram and check the loom wires for continuity would be my first test.
Do you have wiring loom from fuel pump to engine compartment?

[maxstu]

And dismiss the idle stabiliser control unit if you want. The one between coil and amplifier.
The engine will run fine without it. Just connect the two leads together.

[maxstu]

It you are willing to wait until around the T3Bus Meet, l can spend some time at you place helping out.
Alternatively, l can support you remotely....l believe the modern technical phrase being used at the mo......... for a telephone call.

[Smiffo]

Thanks Stuart!

Loom from pump to engine bay I don't have, but don't see it too much hassle to make one up.
I may leave it until after summer anyway. The last thing I want is to be off the road during the nice weather!

The bus meet I doubt we will be there though. ( We already have a holiday booked. When I say "we" I really mean the wife has booked it.) 

[maxstu]

These documents will definately help. I'm pretty certain l pulled them from internet.

[maxstu]

Happy Easter, Steve.

Have you made a decision what to do?

[Smiffo]

Happy Easter Stuart!!

Yep.
I'm going to use the van over the summer, then dive into the DigiJet swap when the autumn arrives.
The theory is I can play with it over a few weeks if needed while I'm not itching to use it for camping.

Worst case, I can swap back if really needed, but Autumn will give me time to persevere.

( My idle issue returned, so it might be the kick I need. )

How is that spanking new DJ engine running?

[maxstu]

Still on engine stand in garage, matey. And still more to do, yet. And that is likely where it's staying until mid-May.
We are busy next week laying new water down at the stables.
I get to re-introduce myself to the joys of using a roofless (it will rain) mini excavator and standing knee-deep in a trench filled with cold water trying to connect old to new...oh joy!
More questions coming on the the rebuild shortly.
Regards
Stuart