DJ2.1 Rebuild

[maxstu]

Also purged air from relief valve. Not a lot, though.

[Stesaw]

Daft question I know stu, but is all the fuel system working?

[maxstu]

Cheers Steve,
Fuel at the pressure test nut by oil tower.

Two things troubling me.

Is timing out by 180 degrees?

To check, l decided to set no 2 piston on the firing stroke and open rocker cover to check position of the inlet rocker for fuel delivery. Never seen so much oil come out of the rocker area before today! Good or bad?

I quickly replaced rocker cover to stop loss of oil.

Had enough for today. Having a beer.

[maxstu]

Still can't get rid of oil light at dash.
Tomorrow with new battery and another go at timing set up will try starting the engine.

Will also check injectors are spraying.

[silverbullet]

I always prefill a new filter before spinning it on, it reduces the time it takes for the ouo pump to fill the oil galleries considerably.

[silverbullet]

PS the high oil level on the dipstick corresponds to an oil level halfway up the cam followers iirc. I posted a pic of this ages ago.
So a full sump would result in oil spillage if you remove a rocker cover.

viewtopic.php?p=8234780#p8234780

[Stesaw]

^ oil when I check rockets etc I always Jack up the side I'm working on or stick it on a ramp so the oil dont come pissing out everywhere, especially annoying when you've put new stuff in.

I had mine 180 out when I did mine stu, just removed the cover, turned the engine til I saw the intake valve on no 1 open and close, kept turning til timing mark for TDC. Then had to refit the dissy drive. I dont suppose it matters if it is 180 out, just swap the leads and it should run just fine. But if you're OCD then.. well out with the drive

[maxstu]

I always prefill a new filter before spinning it on, it reduces the time it takes for the ouo pump to fill the oil galleries considerably.

Did this, SB.

[maxstu]

^ oil when I check rockets etc I always Jack up the side I'm working on or stick it on a ramp so the oil dont come pissing out everywhere, especially annoying when you've put new stuff in.

I had mine 180 out when I did mine stu, just removed the cover, turned the engine til I saw the intake valve on no 1 open and close, kept turning til timing mark for TDC. Then had to refit the dissy drive. I dont suppose it matters if it is 180 out, just swap the leads and it should run just fine. But if you're OCD then.. well out with the drive

Time to reflect and tidy area of numerous tool and stuff.

At least it shows oil is getting pushed around engine.

First task tomorrow, Steve.

Thanks for helping, matey.

[maxstu]

PS the high oil level on the dipstick corresponds to an oil level halfway up the cam followers iirc. I posted a pic of this ages ago.
So a full sump would result in oil spillage if you remove a rocker cover.

viewtopic.php?p=8234780#p8234780

Thanks for this. Least it one thing to not unnecessarily stress myself over......and out!

[Aidan]

m8 grub screw and suitable RTV sealant or similar to make a new blind end for the case checking your depths and if any end stop, into the case tapping then once sealant gone off and checked it doesn't leak then smidge of sealant (you don't want to hydraulic the repair into waterway) and new stud, then recheck upto temp...

[maxstu]

Thanks Aidan,
l used Loctite 577 around the exhaust stud. But left a 3mm void between the stud and breech in to head waterway. 577 is for areas facing coolant and lubricants. Particularly gearbox sump plugs, too. I have £24.50 worth left over in case you need some.

[maxstu]

Injectors are not firing fuel. Lots in the rail and return lines.

Now checking terminals in ECU.
BOTH relays click.
Pump fires fuel to injectors.
Injectors working when attached to tester and battery.
More to come.

[maxstu]

We have a runner!

Firstly, many, many thanks to all contributors.
Secondly, and lm embarrassed to write this, the timing was out by 180 degrees. And that is most annoying as l thought l had set it wrongly in the first place. So two weeks ago, just before installing, l took out dissy and rotated it 180. A big mistake.

A crazy set up. Injection system will not fire if timing 180 out? Is that to do with ECU or Hall sender?

Oil light out. Alternator light on! l can live with that for now.

What's the intial run in procedure? Will set timing at 10 as lm using E5 for running in period.

Going to T3Busmeet is on the cards now. There l can personally thank all who put up with my numptyism approach to rebuilding my WBX.

My utmost appreciation to all contributors over the last 10 month.

[Robsey]

Excellent news !!!
We love a runner.
Well done for sticking with it.