Date:         Wed, 18 Aug 1999 12:59:44 +0000
Reply-To:     Rob Lebo <robl@REDLION-CONTROLS.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Rob Lebo <robl@REDLION-CONTROLS.COM>
Subject:      COLD START WOES (long)

Hi to all and thanks in advance for your help in solving my cold start problem in
my '91 Carat 2.1L.  Symptoms:  Engage the key to start...engine turns over
strong several times but no combustion. Turn key off and try again...engine
starts up but at an almost stall idle, then after a few seconds idle rises to spec
900 RPM. May have to do this 2-3X.  Feather the gas pedal and it stalls. If I try
to drive after start-up it tries to stall again.  This time feathering the pedal helps
keep it running.  After warm-up all is well.  No problems restarting and no
hesitation.
Things I've done so far:  New Temp 2 sensor, new platnum plugs, oil and filter,
idle stabilizer valve removed, cleaned, and verified as operational by hot wiring
to 12VDC and checked again with the engine running, Air Flow Meter cap
removed and resistive trace cleaned, resistance changes over full range of
travel, idle switch adjusted to spec..ie. .0025"-.004" gap and switch is closed
(verified with voltmeter)operation verified with a hot and cold engine, new oxygen
sensor (out of the loop at start-up anyway).  I also checked the engine vacuum
with the gage hooked up to the fuel vacuum distribution thing on top of the
engine and have 10 PSI at idle.  Is this OK??  Also cleaned the throttle body
butterfly (wasn't dirty), checked vacuum hoses and all looked OK, new battery
installed.  Timing, coil spark KV was verified as correct on a diagnostic
machine as well as the funtion of the Temp 2 sensor (timing goes way out
when disconnected on a running engine and goes back to spec when
reconnected).  Distributor cap, rotor and wires have about 25K miles on them.
Cleaned a little pitting on the rotor, cap looks clean.  The only thing I haven't
done is clean ground wire connections and ground strap to the engine.  Has
anyone done all I have done so far and found that ground connections were the
root of the problem?? I bought some electrical connector grease and will use it
after cleaning the ground connectors I can find.  Where are they located in the
2.1L?   The vanagon runs great and gets good gas mileage, no other problems
other than the cold start.   Any and all advice appreciated.  Thanks
Rob Lebo
York, PA