I'd arrive before everyone else I turned up 45 minutes before the
expected start time. I was shown up that there are people more
nerdy than myself, however the stage seemed to be set very nicely
for a day filled with diesel information. Injectors, pumps,
intercoolers, turbos, direct injection, ECU's....we were going to
have it all!.
About half of those who attended the day
posing for the obligatory group picture.
day kicked off with an introduction by Dave Webster of Cooma
Diesel Service (CDS). He quickly listed the topics of the day and
introduced Scott from Denco Diesel (DD) who was going to ably
assist by running some of the workshop sessions. Both these guys
were ably assisted during the day by staff from each of their
shops who willingly gave up a Saturday for our benefit.
kicked off straight away getting into the whys and wherefores of
diesel stuff. VE pumps?, Yep, had several of those. Cutaway inline
pump?. Check!. A heap of items were provided to help assist us to
understand the components that go into diesel injection systems
over the past 30+ years. Also available were items that are yet to
see service in Australia such as Common Rail pumps. Much
discussion was had detailing the progress of diesel injection
technology and where it was heading. In addition we discussed
relevant points about service and maintenance. While a bit techy
at times, no one seemed to glaze over except GC and Dazza who
arrived [late] already looking that way.
Dave Webster shows the gang around the
assembly work area where pumps are assembled prior to
heading off to the test benches.
we were off to the pump room. CDS's workshop is clean. Very clean.
I think it was a surprise to many not to see a dirty and grungy
workshop where cleaning up often involves removing the top couple
of mm of dirt and grease off the floor. In fact, to service
upcoming new injection systems, CDS are installing a Class 10
clean room (cleaner than anything you'll likely experience) in the
next few months.
Dave showing the operation of a 1HZ injector
pump on an early test bench. It also gave graphic demonstration of
the nasty affect a pusher pump has on the operation of the
were provided of a
Toyota 1HZ VE (rotary) fuel pump and also a high pressure VE pump
from a Toyota 1HD-FTE. The noise was deafening!. Fingers in ears
helped, but you could still hear what was happening. Hmm, maybe
all that noise under the bonnet isn't combustion noise but rather
just the pump rotating and injecting.
A newer High Pressure 1HD-FTE pump on the
computerized test bench. A tough environment on the ears...
people were so scared of the noise they stood outside the glass
Live display of injector testing on the dual
stage injectors like those found on the 1HD-T, 1HD-FT and 1HD-FTE
the pump room we went into the injector room. A whole room
dedicated to just servicing the injectors!. The precision required
these days to produce a quality product shows when companies don't
use analogue gauges, but prefer to manufacture expensive digital
testing equipment. The result?. Exact and repeatable pressures on
injectors all the time. This translates into perfectly matched
injector sets for maximum power and smoothness. Injector operation
was discussed and explanations were provided why lapping injectors
is not something to be contemplated these days. (The equipment is
there for injectors that specify lapping, but nothing manufactured
in the last 30 years is designed for hand lapping).
a short break for a BBQ lunch it was back into tech talk.
Discussions went on covering intercoolers. Designs, construction
and fabrication were covered. We had the pleasure of additional
input by George C on this topic. His background in thermodynamic
modelling and hands on experience at Safari/Air Power systems
provided additional reassurance that intercoolers were a good
thing for all turbo diesels regardless of where you live. Peoples
fears of overheating the coolant radiator (and hence engine) were
put to bed with some other myths. Bottom line: If you can afford
it an intercooler is an investment in increased reliability with a
little extra power to boot.
Dave had a good display of the variety of
intercooler construction types found today.
Close up of one of the better intercoolers
out there. Internal and external finning substantially increases
the intercooler's efficiency.
part of any service work you want to KNOW that the end result has
been worthwhile. With the large volume of work that Authorised
diesel fuel shops do, they know exactly how much power and torque
your vehicle should be making. The use of a dyno verifies that
things are tuned properly, and fine tuning can be undertaken with
measurable results noted. One thing I’ve noted over the years is
that dyno results in themselves are only part of the picture and
may not always show clearly that parts are worn. Experience,
specialised training, and proper testing equipment are all part of
what is required to provide a quality product and service.
Norm's car on the dyno. Norm was doing his
best to suck the gut in.
diesel systems incorporate ECU’s and electronic readers are used
to verify that all sensors are working correctly. Again, this
demonstrates that there is more to servicing than just a quick
clean of injectors and adjusting pump timing.
Turbo balancing machine.
were also on the agenda. Looking at how turbo’s are balanced to
within less than a gram on specialist machinery…. The overheads
in a properly equipped workshop sure are high!. Reliability of
turbo’s got raised and was duly dispatched. Turbo’s should
last the life of a motor in a properly maintained engine. As
someone who has had an engine without, then with a turbo, I’d
never be without a turbo again.
Talking turbos... A turbocharger's rotating
group gets the once over.
too soon (after 8 hours!) our day ended. The consensus was that it
was a great day provided by CDS and DD and everyone went away with
Some of the gang during the afternoon's
Dave Webster (centre) and his team up
against the wall as questions were fired at them.
done Cooma Diesel Service and Denco Diesel!.
you’re interested in attending a DID day then email mailto:firstname.lastname@example.org
and let the Grinch know. These days are only held in Canberra and
are not suitable for children or bored spouses.
you at DID2,
People waiting with baited breath as Brian's question about
installing an external venting blow off valve on his 1HD-FTE was
Mazza, Dazza and GC discussing "stuff" during the lunch
Maz sneaking up behind Darren whilst he was giving Ian an earful.
Norm getting his hands dirty - now a rare sight.
What began as a sincere attempt at fixing an under powered Nissan
by installing a Toyota 1HZ engine, Daz seized on the opportunity
by attempting to make off with the engine to fit to his Prado.
Darren and GC's trip to Canberra
The weekend got off to a side splitting start. After meeting with
Ian and a fairly indigestible pub dinner, Ian discovered that he
had left the key to his steering lock at home. After a valiant
attempt at trying to break the lock's weld with a spanner - only
to realize that the lock is stronger than the steering wheel, Ian
relented and took Daz's Prado home to retrieve his key. It gave
Daz, Norm and GC plenty of time to return back to the pub for some
Home for a couple of nights. Ian graciously allowed Daz and GC to
set up camp in his shed. Daz and GC apologized for the state they
left it in.
Daz hard at work slaving over the cooker. Breakfast is one of his
The trip home included a "spirited" drive over Thredbo
and crossing the Murray River. Daz has his foot to the floor in
1st high trying to build speed so that he drenches GC who was on
the bank photographing. Luckily Daz drives a 1KZ-TE powered Prado
and all he managed to do was to splash GC's "going out"
Daz laughing like a naughty school girl after GC tried to take a
chunk out of him for splashing his good thongs.
Lunch time, somewhere over the Murray River. Daz's Prado looks
Daz contemplating the route home from Limestone Creek camp. He
spent more time looking at the maps than was necessary.
After a little reversing incident, Daz had to spend a fair deal of
time and effort to get the dirt out of his blocked exhaust. If
he'd hit the ditch any faster he would have compressed any carbon
based particles into diamonds.
An ideal camp spot complete with background mist - probably from
On GC's advice, Daz didn't bring any sleeping stuff other than his
mattress and sleeping bag. He did a great job of rigging up a
couple of tattered tarps to keep the night dew off while GC slept
soundly in his cosy swag.
Morning brought out Darren's evil streak. Nothing and I do mean
nothing was safe from him.
The morning's tally of destroyed cans, stubby holder and drink
Limestone Creek hut. This one is on the verge of falling.