Date:         Mon, 29 Sep 2003 06:27:49 -0400
Reply-To:     Dennis Haynes <dhaynes@OPTONLINE.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dennis Haynes <dhaynes@OPTONLINE.NET>
Subject:      Re: 2.1 fuel injection problem
Comments: To: RAlanen@AOL.COM
In-Reply-To:  <a2.3cafa399.2ca95fdc@aol.com>
Content-type: text/plain; charset=iso-8859-1

Wiring problem with the O2 sensor or more importantly the ground. Do you
have a ground wire connected at the base of the oil breather? If so,
this is the culprit. Relocate it. The plastic tower makes a lousy ground
connection. I usually place this connection under one of the screws for
the fule pressure regulator.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Frank Condelli
Sent: Monday, September 29, 2003 6:14 AM
To: vanagon@GERRY.VANAGON.COM
Subject: 2.1 fuel injection problem

        OK, gurus I have a problem here that I have been unable to
resolve 
and am asking your collective help.  
       1991 2.1 engined Vanagon.  Running way too rich, black smoke
pouring 
out of exhaust tail pipe at idle and under acceleration.  At cold
startup it 
seems to be running perfectly, no black smoke, when the engine warms up,
you can 
hear it change rhythm, the black smoke starts pouring out the exhaust.
Let 
it sit until the engine goes back to cold and restart it will run
perfectly 
until it warms up, drop in idle then black smoke again.
       Unplugging the O2 sensor cures the problem, so I immediately
though it 
was a bad O2 sensor.  I have done the following and NONE has resolved
the 
issue.  New CAT, new OXY sensor (tried two), exhaust system is not
leaking 
anywhere.  Checked & replaced Temp II sensor (original was giving same
readings as 
the new one but replaced anyways). Checked throttle position switch,
mechanical 
clicking and continuity test, OK.  Checked AFM, all readings as per
Bentley, 
swapped in an AFM from a perfectly running 2.1, made no difference.
Checked 
air intake track, clear and free of obstructions.  Tried swapping
computers, 
two different ones actually, all the same.  Checked all wiring from
computer 
terminal plug to respective sensors, did all tests as per Bentley, all
OK.  
Checked all grounds, all OK. Idle stabiliser valve humming, unplugging
it will kill 
the engine, unplugging it by the yellow connector on the firewall drops
the 
rpm.  Swapped in an Idle Stabiliser Control Unit from a known working
2.1, made 
no difference.
       So..........WHAT am I missing ????

Cheers  

Frank Condelli
Almonte, Ontario, Canada
<A HREF="http://members.aol.com/BusFusion/bfhome.htm">BusFusion</A> a VW
Camper camping event, Almonte, ON, June 10 ~ 13, 2004
'87 Westy & Lionel Trains
Member: <A HREF="http://www.vanagon.com/">Vanagon List</A>, <A
HREF="http://www.bcn.net/~limbo/">LiMBO</A>, <A
HREF="http://www.westfalia.qc.ca/">IWCCC</A> & <A
HREF="http://www.ccvwc.ca/">CCVWC</A>  
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
<A HREF="http://members.aol.com/Fkc43/stebro.htm">STEBRO/Vanagon
Stainless Steel Mufflers</A>  
<A HREF="http://members.aol.com/Fkc43/busindex.html">Frank Condelli &
Associates</A> or http://frankcondelli.com