TheSamba.com :: View topic - Engine rplcmnt: Need engine cylinder numbering & rel tro

Mon Jul 11, 2005 8:32 am

Hello all -

Replaced my 84 Westy engine w. a rebuilt 85 I purchased. Compression checked ok. Probably had been sitting a while, as had my van. Gas has been dormant for 2+ years. Added fuel cleaner to help.

Got new engine installed and cranked without the plugs to get gas going. Sounded pretty good. However, once the plugs are in and attached to the distributor, the engine wont turn. Sounds like it wants to, but cant get over the hump.

I figure the problem is I have the distrubutor firing the plugs in the wrong order. I found the firing order in the Bentley, however, I cant figure out which cylinder is 1 - 4. So number one question is does anyone know how the cylinder order is arranged in a 1.9L? Cant seem to find it in the Bentley. Seems like this info should be in there.

Also, after attempting to start the engine several times, even with plugs out, and then in, after removing the plugs, i have no smell of gas at the plug cap. I did confirm presence of gas at the intake manifold however (fuel pump ok). Not sure how much of a gas smell I should get at the cap.

Any help with the problem would be appreciated.

Thanks,
Alex

Mon Jul 11, 2005 11:14 am

Passenger side front =1, back =2
Drivers side front = 3, back =4

Do this:

Put on your fuel pressure gauge and test (with your Bentley manual in hand) to see if you are at the minimum psi to get the engine started. About 26 psi. Somewhere along the fuel rail is a place to test the pressure. Mine is between #3 and #4 cylinders, but I don't know about yours.

The gauge looks something like this.... http://www.thesamba.com/vw/forum/album_page.php?pic_id=105556

Do the Bentley volume test while you are at it. You have to have adequate fuel pressure and adequate fuel volume to get the thing to run.

Then pull out the injectors to see if they are actually spraying correctly as per the Bentley manual. I sent all of mine off to www.cruzinperformance.com to have them cleaned and calibrated for like $12 each, so there would be no question. None of the fuel delivery system components from the tank to the injectors likes sitting around with dead gas in them. Causes them to "mung up" (a Georgia term that says it so well) and not deliver the squirt of gas we so long for.

Make sure your battery is fully charged. Minimum voltage to get the FI thing to even start is about 9.8 volts I want to say. The Bentley will know.

The injector actually is timed to inject fuel by the distributor sending an electronic signal through the ECU to the electrical connection on the injector. You can tell if the electrical portion is working by sticking a "noid light" or a 12 volts test lamp into the injector connector terminals and running the starter to see if the test light blinks on and off (that is good). No blinking indicates that there is no current reaching the injector and electrical connections are suspect.

Let us know what you find out.