Date:         Tue, 7 Feb 2006 19:08:23 -0500
Reply-To:     Roger Sisler <rogersisler2000@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Roger Sisler <rogersisler2000@YAHOO.COM>
Subject:      Re: Just replaced the throttle switch and am having drivability
              issues

Vanagon fixed! I think. No fried wiring and no fried switches.However,
the connectors for the auxillery  air regualator and throttle switch were
mixed up.The throttle switch was getting zero volts with the key in the run
position.Should have been getting 5 volts.12V when the vehicle was actually
running is what was happening,but I didnt check voltage then.What I did was
change the ECU like Bentley says.Fried switch and no suspects unless the
voltage was measured with the vehicle running. 5 volts were going to the
auxilery air regulator when it should have had the 12V.

   I was working in that area of the engine recently doing a psudo head
gasket repair,but I do remember reconnecting the connectors in the proper
locations.I mean the 1.9 has the connector going to the throttle switch at
the intake runner.The connector bolts to the runner. The wiring is just
long enough to reach the correct spot.Also, after 21 years, the wires
get "set" at a certin shape and remember that shape when disconnected.Just
enough wire to do the job, and no more(at least in my WBX).

   What I found was lots of extra wire in the connector going to the
throttle switch,and the connectors mixed up.Well I'll be. I think VW must
have had some concern about this and made the wires the length that they
did,but it didnt keep the reverse from happening like it did here.

   None of the wiring was fryed and the switches were all still ok.Even
after I had run this new set up today, long enough to fry things good. I
tested the wiring and switches for continuity seperately, and all hooked up
together, from the ECU.I tested from the ECU to the throttle switches for
voltage,and for voltage in the wires when disconnected from the
switches.Clicked and unclicked.Unclicked and clicked.

   About 5 V at the throttle switch now,and 12 v at the auxillery air
regulator.Yaaaaa!But things didnt go all that smoothly.When I finally test
drove a few minutes ago, I still had some kind of problem.I ran the engine
and was not getting continuity at the switch.I drove around an figured that
I did destroy another wire or switch afterall . The van surged and ran
poorly.Identical polarity from switch to switch seems to be importiant in
the early WBX throttle switch set up. I switched the connectors on one
throttle switch and everything seems ok now.This,after lots of testing
again.

   Just test drove it yet again and I am having some surging idle,but this
may be timing issues as I had shifted it around by ear when I suspected
that this may be contributing to the problem.The poor drivability is
corrected and I can pull from very low rpms(1000)and still not get
bucking.I guess I will watch this for a few days and decide where to tweek
things.

   The throttle switch in the early WBX is in a bigger box than the switch
in the later vanagons.Same with other VW autos. Maybe they are more
substantial inside and hold up a bit better to this kind of botching.


   Another day another problem,it seems.Gets old sometimes.Thanks for all
the suggestions and wisdom. Hope other 1.9 owners can avoid this mess I
just saw.