In addition to all the other good = leads for the problem, I would add, check the fuel filter, especially since you = described the rotor & cap as being in very poor condition.  Sounds like = the previous owner wasn't too careful with keeping his Westy = tuned.
 
Good luck.
Bob
87 Westy "RDRUNR1"
-----Original = Message-----
From: William Grace <williambhgrace@HOTMAIL.COM= >
To: vanagon@GERRY.VANAGON.COM <vanagon@GERRY.VANAGON.COM&g= t;
Date: Sunday, June 24, 2001 7:30 PM
Subject: 85 cuts out/dies = when hot - HELP! stranded in Pueblo, CO

I'm stuck in Pueblo, CO with my 85 Westy and my incredibly good = spirited and encouraging partner, Kerri.  I would appreciate any ideas = before I visit the VW dealer in the morning.

Background:  = I just bought the Westy in Tennessee, and am driving it back to = Seattle.  It ran great from Tennessee to Pueblo, and upon arriving in Pueblo today, and = driving in stop and go traffic for about 15 minutes in 97 degree heat, the = symptoms started.

Symptom:  The 85 Westy's (with manual trans) engine cuts out, hesitates, runs irregularly, and finally dies altogether when it gets hot.  This progression takes about 30 seconds.  While the = symptoms are happening, I can kind of "feather" the throttle, and keep it = running for a little longer - especially if I can get it up over 2000 RPM.  = Immediately after it dies, it cranks fine, but won't re-start.  After letting = it sit for about 15 minutes, it will start and run normally for about 5 = minutes, then the symptoms start over again.  I've repeated this process 5 = times now, and it acts the same each time.  The coolant temp gage reads = normal (about mid-scale) all through this, but I'd guess the temp in the = engine compartment was the highest it's been since I picked up the van.

 

Here's what I've done so far, and none of this has changed the = symptoms at all:  When I looked at the engine after it died the first time, = the hose from the crankcase breather to the air intake boot (about 1 inch = diameter hose) was sucked flat in the middle.  It had lost all it's = stiffness - heat? and was floppy.  I replaced it with a nice stiff hose of = just the right size from Auto Zone.  Free too - it was a scrap.  = Thanks Auto Zone.  It didn't do any good, though, still had the exact same symptoms.  After that, I replaced the air filter, cap and rotor, = plugs, plug wires, all of the little fabric coated vacuum lines, and fuel filter.  The rotor was really bad looking - the center contact = was broken off from the metal strip leading to the spinning rim piece.  Must = have been sparking across the little gap.  And two of the plugs were loose.  Anyway, that's all interesting, but none of it = helped.  I brought all those parts with me "just in case", and it's Sunday = afternoon, so might as well put 'em in, huh?  I also tried to replace the O2 = sensor, but couldn't get the old one unscrewed.  It is full of gas & = oil level's fine.

Here's what I haven't done:  Any real troubleshooting to = isolate whether it is a fuel delivery problem or a spark problem.  I = guess I'm going to leave that for the dealer in the morning, but any thoughts on = these symptoms would be greatly appreciated.  Thanks.



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