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Date:         Fri, 16 Oct 2009 07:41:54 -0400
Reply-To:     Greg Potts <greg@POTTSFAMILY.CA>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Greg Potts <greg@POTTSFAMILY.CA>
Subject:      Re: Surging engine
Comments: To: Paul Chubbuck <paul@TAKINGFLIGHT.NET>
In-Reply-To:  <000801ca4df8$2a9079a0$7fb16ce0$@net>
Content-Type: text/plain; charset=ISO-8859-1; format=flowed

Hi Paul,

CIS injection can be a PITA to deal with when it isn't running right, and a lot of parts are hard to find or very expensive.

Here are three possible solutions not previously mentioned listed from cheapest to dearest.

You can get a weber carb kit for that engine for around $500. You would also need a new low-pressure fuel pump to supply the carb, but that's only $50 or so.

Another option would be to swap the cylinder head to that from a later model 2L Golf or Jetta and then convert to Digifant fuel injection as was used in the 1986-91 vans. In practical terms you'd probably need a donor car to do this swap since you would need the wiring harness, computer, intak, etc.

Third option: Consider replacing the engine with something later from a golf/jetta. It'd be a simple bolt-up mechanically, though the electronics and fuel system would take some rework. It's certainly got to be a LOT cheaper than $12K though, and if you start with the right donor car you get a fresh(er) engine as well.

If the shop won't consider these options you are dealing with the wrong people for the care of that vehicle.

Happy Trails,

Greg Potts 1973/74/79 Westfakia "Bob the Tomato" 1987 Wolfsburg Weekender Hardtop www.busesofthecorn.com www.pottsfamily.ca

Paul Chubbuck wrote: > For over a year, my Vanagon engine has been surging badly, especially when > the accelerator is fully depressed, as it frequently is at highway speeds. > The rate of surging at highway speeds is approximately 2 cycles per second. > The surging can be minimized by backing off at bit on the accelerator, but > since the engine is underpowered for the vehicle, it is not acceptable to > use anything less than maximum acceleration. At street speeds it is much > less noticeable but even then there is often unsteady acceleration. It > makes driving unpleasant and rough. Sometimes the problem will suddenly > cease and there will be smooth running for anywhere from a few seconds to > several miles, but otherwise, it is there most of the time. > > It is a 1982, originally diesel, but converted before I owned it to what I'm > told is an 86-92 Rabbit/Fox engine. The computer has Bosch number 0 280 800 > 104 (105) on it. It is fuel injection. > > I have been told by two different seemingly competent shops that the problem > lies in a part numbered Bosch 0 438 101 005, which I believe is called a > fuel flow meter or a fuel injection pump. Not sure of that...I'm not a > mechanic, as must be obvious. > > The first shop to work on it had it back at least 5 times before they gave > up. They tried cleaning and adjusting that component to no avail. They > couldn't get a new part and tried replacing with a used part and said the > other used parts performed worse than my own. They also replaced the O2 > sensor. > > The 2nd shop said replacement of that part would cost me $2000 because the > part is not made any more. They offered to do an engine conversion to a > Suburu for $12,000! > > Can you tell from the symptoms if this part is really the culprit? Is there > any way to replace this part at a reasonable price? > > Thanks very much in advance. > > Paul Chubbuck in Fort Collins >


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