Date:         Wed, 14 Nov 2007 16:04:16 -0800
Reply-To:     neil N <musomuso@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         neil N <musomuso@GMAIL.COM>
Subject:      Now: Thanks! (+ Report. Long.) Was: Leaky ... fuel injector? (and
              fuel press. regulator)
Content-Type: text/plain; charset=ISO-8859-1

Hi all.

First off, many thanks to all for the ideas/suggestions regarding
getting the engine in my parts Vanagon to run. It runs now, though I'm
not totally sure of it's condition.

For the benefit of the curious and other newbies here's what happened.

The PO unknowingly ran engine, or started it many times, until the
crankcase was FULL of gas/oil. Turns out the engine had a faulty fuel
pressure regulator (broken diaphram). I took it off and found I could
blow air into the small opening (NON fuel side of diaphram) through to
the fuel side. A bad thing. As such, when running, being started, or
just sitting overnight, fuel would go past the diaphram and into crank
case via a small tube that connects to the air intake distributor.
That was most of the problem.

Solution.

Drained the gas/oil out of engine, replaced the FPR, squirted oil in
each cylinder, turned the engine by hand with new oil in it (filter
too) until it turned easily. Spun it with the starter quite a few
times, cleaned the plugs, double checked everything and fired it up.
It started right away! But was smokey as hell and stalled. I figured
it was burning off the oil I had squirted in so tried a few more
times. It still burned blue-ish, but I thought there was more to it. I
checked the plugs. They had gotten black. Too rich. The distributor
was loose too. So I timed it statically. Eventually got that close
enough. I also did a visual check on the FI's. On one cylinder, the
injector looked like it had a melted tip. It was slightly shorter than
the other beside it. I replaced the pair on that side. It ran better.
Then I realized (Duh. I'm so "old school") that I needed the air
filter housing on!! Need that air sensor connected! Put that on, it
ran WAY better. This explained the fouling plugs.

It seems to have good power. It revs up great. The blue smoke cleared
up, ( I assume it was smoke resulting from a rich mixture due to a
lack of the air sensor and possibly due to a bunged FI) but then it
*seemed* to be blowing some white smoke. Actually more totally moist
exhaust than white like a blown head gasket. Anyhow...... It was too
much smoke overall and I figured I'd given the neighbours enough for
the day, so I shut er' down.

The engine has a light clattering noise which I think is lifters, but
I have no idea what happened to the engine when it stopped running.
But right now it revs up great and idles well. (given that the timing
is likely off a bit)

Too bad. I'm suspect of the white smoke. I think this engine is core
material. Good news is that I know an air cooled starter will work in
a WBX tranny, and that the ECU etc. is likely fine. Maybe someone can
use that stuff. The engine sure sounds powerful. I may do a
compression test for the halibut. (need to buy the tool first. a good
investment)

So again, thanks much for all the help. I learned lots.

Cheers,

Neil.

--
Neil Nicholson. 1981 Air Cooled Westfalia -
"Jaco"  (Bustorius)

http://web.mac.com/tubaneil