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Digijet wiring harness rebuild
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Lulu1984
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PostPosted: Sun Apr 10, 2016 9:27 pm    Post subject: Re: Digijet wiring harness rebuild Reply with quote

Hi there. My 1984 westfalia is running rich and won't pass smog. Everything is new except wiring harness, ecu and distributor. I need some help please. Can someone tell me the difference between the 2 ECU part numbers:
Digijet
025 905 021
025 905 021c
My van currently has the top part number in it; I am wondering if the previous owner may have swapped out the original ECU with a non california version. Any thoughts?
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t3 kopf
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PostPosted: Mon Jun 15, 2015 1:13 pm    Post subject: Reply with quote

I got all my wire, heat shrink and other consumables from my local electronics shop. Good call on the shopping cart link.
As far as the kit, I've still got some other things to do before I can start ordering bulk parts, but it is a possibility of course. I still have another harness to do.
The problem is that I just saved up enough for kennedy engineering's basic ej22 conversion kit and i'm gonna pull the trigger. I'm gonna use my current engine and all my digijet stuff after that on whatever my next project may be. Probably a bay or a ghia.
With all that and the fact that I work 50-60 hours a week, itll be at least a year before I could do something like sell harness kits.
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atomatom
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PostPosted: Mon Jun 15, 2015 12:24 pm    Post subject: Reply with quote

i think this is the best fit for wire. but that is just a guess: http://www.digikey.ca/product-detail/en/751816%20VI005/751816%20VI005-ND/3716095

wire is tricky; prices are all over the place. this is $40 for 100ft. violet.

Code:
Product Photos   HOOK-UP STRANDED VIOLET
Product Training Modules   Basics of Wire and Cable
Standard Package ?    1
Category   Cables, Wires
Family   Single Conductor Cables (Hook Up Wire)
Series   751816
Cable Type   Hook Up
Wire Gauge   18 AWG
Conductor Strand   16/30
Conductor Material   Copper, Tinned
Jacket (Insulation) Material   Polyethylene (XLPE), Irradiated
Jacket (Insulation) Diameter   0.109" (2.77mm)
Jacket (Insulation) Thickness   0.031" (0.80mm)
Length   100' (30.5m)
Voltage   600V
Operating Temperature   -40C ~ 125C
Jacket Color   Violet
Ratings   UL Style 3173

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atomatom
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PostPosted: Mon Jun 15, 2015 11:04 am    Post subject: Reply with quote

here is a cart link to add all those parts in one easy click: http://www.digikey.ca/short/71zbf5

what i'd also like is a decent choice of wire to go with it, and perhaps some shrink wrap. tons of options. if money was no object, i'd go for the 500oC wire, but $$$. high temperature wire makes sense though. looking at hookup wire, not clear which is best. will update as i figure this out. Smile
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atomatom
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PostPosted: Mon Jun 15, 2015 10:49 am    Post subject: Reply with quote

ok, so i went to do this. easy enough, but, how many of each! Smile

t3 kopf and edited by me to add qty wrote:

1) 4 A106202-ND Fuel injector connector housings
2) 4 A105234-ND Fuel injector connector boots
3) 16 + 2 just in case A107135CT-ND 15-20 AWG crimp terminals (for ecu connector, injectors, etc)
4) no idea? A27935CT-ND 14-18 AWG locking female terminals (female spades)
5) no idea?A100857CT-ND 10-12 AWG locking female terminals (larger gauge female spades for splicing in the relay box)
6) no idea? same as 4? A27922CT-ND 14-18 AWG locking male terminals (male spades for the relay box)


i could just order a bunch for 4-6 and hope i get it right. 25 is probably too many, but $5.

did you source the wire and heatshrink from digikey as well?
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atomatom
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PostPosted: Mon Jun 15, 2015 10:03 am    Post subject: Reply with quote

i totally appreciate your attitude to not ripping people off - and in sharing. but i'd happily pay some mark-up to save me the chance of making a mistake in ordering the wrong parts. and you could probably even get a better rate from digikey if you buy in larger quantities.

the bigger hassle, perhaps, is that once people pay money, they expect support. like i did all this wiring, and it doesn't work. help. this kit would not be as simple to install as some other kits. so, i can see that being a pain.

in my mind, the wiring is as critical as the fuel lines not only for running well, but also for fires. although it gets a bit of noise, it doesn't get enough attention.

i'll try making the shopping list on digikey, but you see, it'll probably take me at least an hour or so to go through that, double checking the thread to see if i got all the parts i need. if not, then an extra order, 2x shipping, etc, more checking, time, and so on.

i really have no problem buying kits from samba guys who share their knowledge. i'm happier when i can do that and the markup goes to the person who did the r&d rather than a vendor. maybe i should offer them, and send you commission? Smile
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t3 kopf
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PostPosted: Mon Jun 15, 2015 9:49 am    Post subject: Reply with quote

That would be kinda cool, but then i would just have to order all the parts and i would have to add more to the cost to make any money, so it would be more economical for people to just use the part numbers i included in this thread. I would feel like i was ripping people off if i just ordered parts and then resold them. If they were to put this thread in the FAQ it would help. I know theres already one with the part numbers in there, but these part numbers are updated and are a lot less expensive.
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atomatom
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PostPosted: Mon Jun 15, 2015 9:32 am    Post subject: Reply with quote

t3 kopf; would you consider selling a DIY kit that contains all the connectors? i'd love to buy one; the main issue with ordering these connectors is the shipping can end up as expensive as the parts if you don't order many, and/or order the wrong part, so more shipping/delay.

maybe it makes sense to sell the wire too? i'm not sure. if you had enough people buying kits you could have different colours for each signal.
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t3 kopf
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PostPosted: Tue Mar 17, 2015 6:13 pm    Post subject: Reply with quote

May be a different story with an AC harness. His response to my inquiry about his digijet harness was 5 weeks to rebuild mine for nearly 600 dollars and he reuses everything but the injector connectors. I'm sure hes better than i am and he should be because mine aren't being sold to people. Digijet harnesses are a lot different than l-jet harnesses.
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GreenMachineVW
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PostPosted: Tue Mar 17, 2015 6:01 pm    Post subject: Reply with quote

t3 kopf wrote:
True, and i'm sure he does an amazing job, however nearly all the parts are reused. For less than a hundred i've basically done the same thing for myself.

That's odd: on my 1983 Federal Air-Cooled harness that I got from Kyle, only the ECU and double relay connector were reconditioned, and the ECU looked new, the double relay slightly yellowed. I cannot speak to the quality of your work, but Kyle's harness was truly impressive, and I have spliced a wire or two myself ... http://www.thesamba.com/vw/forum/viewtopic.php?t=605990&highlight=
Image may have been reduced in size. Click image to view fullscreen.
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t3 kopf
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PostPosted: Tue Mar 17, 2015 4:53 pm    Post subject: Reply with quote

I got a nice day out here, finally finished up most everything else on the van and pulled it out of the garage. The wiring harness works great and the van is running just fine. I did a coolant bleed and set the timing. Still need to hook up the stereo. Ill take it for a shakedown run this week when i get time.
So now i have 1 new harness in the van,1 new backup, one used harness ready to rebuild and 1 more in the mail to wait behind that one. I may modify my next two to put the ecu under the seat like a digifant van. Might also incorporate the tailight and temp and oil pressure sender harnesses to make it all one clean harness. Lots of possibilities here.
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t3 kopf
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PostPosted: Sat Feb 28, 2015 4:28 am    Post subject: Reply with quote

True, and i'm sure he does an amazing job, however nearly all the parts are reused. For less than a hundred i've basically done the same thing for myself.
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tclark
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PostPosted: Fri Feb 27, 2015 10:10 am    Post subject: Reply with quote

where you might get the low down on all hard to find parts is
kyle
http://kyleautomotivespecialties.com/home

he does brand new 1.9/2.1 harness
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Vanagon Nut
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PostPosted: Thu Feb 26, 2015 10:28 am    Post subject: Reply with quote

thanks t3 kopf. That's helpful to know.

I recall a post here about a 2.1 harness intermittent failure. IIRC, the issue was at a tight turn in harness, but was curious to know if something like a burn mark might indicate where one could wiggle, twist, etc., a harness for an intermittent connection.

Neil.
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t3 kopf
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PostPosted: Thu Feb 26, 2015 9:58 am    Post subject: Reply with quote

The OE wires were fine under the loom, even at the discolored areas. The corroded points were at the connectors. Especially at the relay box, the temp 2 connector, the injectors, grounds, aux air connector and idle switch. At the injectors on the #1 and #2 side and the temp 2 connector, the wires are exposed to the heat originally. There were some burnt areas there causing an extra 2-3 ohms of resistance on a continuity test. it was far enough up the wires that splicing in a new connector alone wouldnt do. That burnt looking section of loom on the right side of the picture was only in the loom itself.
It seems that the factory didnt do a great job of crimping a lot of these connectors. There are a lot of them that have exposed strands at the crimp which lets in moisture for sure.
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Vanagon Nut
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PostPosted: Thu Feb 26, 2015 9:42 am    Post subject: Reply with quote

great build and neat link to the Bay forum. Super useful. Thanks.

re: pics of your old harness,

http://www.thesamba.com/vw/forum/viewtopic.php?p=7...ps#7568730

Did you open up any of the old harness further up the wires? I'm curious if there's any failure (or pending failure) points at wires under discoloured sections of OEM loom or how far corrosion typically had crept up any of the wires.
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1981 Westy air cooled to 15 ABA swap: http://tinyurl.com/y9n4xob8

50 ABA Swap in to '88 Westy: http://tinyurl.com/yap5hpwt

Vanagon VAG GAS engine swap Google Group:
https://tinyurl.com/2f24rmh

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t3 kopf
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PostPosted: Thu Feb 26, 2015 6:58 am    Post subject: Reply with quote

geo_tonz wrote:
t3 kopf wrote:
are you talking about the connector to the hall generator on the side of the distributor? digijet or digifant (although i think they're the same one) if so, thats a different connector from the injectors but van cafe sells a pigtail. otherwise, the pins are the same as what goes in the ecu connector, temp 2, aux air, etc


Yes 2.1 Digifant Hall Sender Plug. Van Cafe's is $75...An equivalent from Digi-Key (If it exists) would be significantly cheaper I imagine if I could figure out an equivalent connector. Thanks anyway.
Nice work!


It turns out the hall connector part number is AMP 926076-1. It is obsolete by te connectivity, there are no reported vendors and is pending a new part which is AMP 926076-2 but isnt being made yet. The same is used for digijet and digifant. All originally came with the wire clip but most have broken and arent used anymore. I have always used mine with no clip. You could also find the connector on some rabbits, cabriolets and older golf headlight plugs and some saab models. The vans i looked at all were missing the clip. The boot part number is 281 919 141 A. The flat connector with no boot can be found still from vw classic parts in UK for about 2 euros. It is vw part number 211 905 327. The best you could do i would say is scour the pick and pull junk yards for rabbits and cabriolets to find one with an intact clip and use the digikey new pins to rebuild them. Since nearly every one i have come across has the wire sheathing cracked at the boot, its a good idea to stock up on these if you wanna continue to use your OE digifant. Either way, there are still better options than paying 75 dollars for a pigtail when you can just repin yours for 10 dollars in wires and connectors. I have 4 of them still usable (one of which in use) and Im probably not gonna get rid of them because i wanna keep my digijet for any future vehicle endeavors Wink . A few hours of googling might bring you some luck somewhere. good luck.
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t3 kopf
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PostPosted: Tue Feb 24, 2015 12:27 pm    Post subject: Reply with quote

JPrato wrote:
t3 kopf wrote:
Heres a list of the connectors and such sourced from digikey, used for the digijet harness,.....

A106202-ND Fuel injector connector housings
A105234-ND Fuel injector connector boots
A107135CT-ND 15-20 AWG crimp terminals (for ecu connector, injectors, etc)
A27935CT-ND 14-18 AWG locking female terminals (female spades)
A100857CT-ND 10-12 AWG locking female terminals (larger gauge female spades for splicing in the relay box)
A279922CT-ND 14-18 AWG locking male terminals (male spades for the relay box)


Thanks for posting the part numbers! The last one has an extra "9" in it. It should be A27922CT-ND



good catch.....fixed!
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PostPosted: Tue Feb 24, 2015 5:16 am    Post subject: Reply with quote

t3 kopf wrote:
Heres a list of the connectors and such sourced from digikey, used for the digijet harness,.....

A106202-ND Fuel injector connector housings
A105234-ND Fuel injector connector boots
A107135CT-ND 15-20 AWG crimp terminals (for ecu connector, injectors, etc)
A27935CT-ND 14-18 AWG locking female terminals (female spades)
A100857CT-ND 10-12 AWG locking female terminals (larger gauge female spades for splicing in the relay box)
A279922CT-ND 14-18 AWG locking male terminals (male spades for the relay box)


Thanks for posting the part numbers! The last one has an extra "9" in it. It should be A27922CT-ND
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t3 kopf
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PostPosted: Mon Feb 23, 2015 11:05 pm    Post subject: Reply with quote

Have not ran it up yet. I still have a few things going on. I need to do a coolant fill/bleed, change oil, and its on jackstands in the garage waiting on new front brakes in the mail. I'll update when I run it though. Its too cold up here still!
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