HELP... My '81 aircooled 2L Vanagon Westfalia isn't working

[dfbland]

I am new to the world of Volkswagens and I was told I would have days like this, I just never thought those days would feel like weeks.

I acquired an 1981 Vanagon and it had been sitting around for a couple of years, so I gave it a little TLC and put it to good use. I changed all the filters and had a Volkwagen Mechanic look at it for any issues to which he informed me about a small vacuum leak that he had fixed. I had inspected the fuel lines and tried to find any issues with grounding problems (only to find a network of wires that someone had messed up, but the van still ran great with lots of power).

After the first month I came to a problem with ignition, I checked the fuel lines again and found that the fuel flowed great, I checked the electrical lines and it turns out the replacement of the distributor cap and coil fixed that issue. I was back on the road and the van ran great.

A week ago my van started to have some starting issues, it just didnt feel like starting too fast and left me worried in a couple of situations, but I couldn't find any issue and it still ran great, so I let it slide until I could hear a small leaking sound, but I couldnt find its location and my van still ran fine.

A few nights ago the van started to buck and act funny, losing all power, the vacuum said it wasn't getting very much air until I started to go down hills fast or I rev'd the engine up. I got it home and overlooked the problem to find that small leak was still there and I was determined to locate it and fix the issue. I took out the hoses from the air filter, the S bend, the throttle and even took out the auxiliary air valve (it had come lose and the hose needed to be replaced) only to find I couldnt find a leak, I put it all back and checked for cracks or anything that should be replaced (it all seemed to be fine).

I went to start the engine and instead of having problems starting, it started to turn over right away, but the engine died RIGHT AWAY as I let go of the key in start position, so I looked again at the engine to find a couple of more small issues I was sure would fix my problem, I sealed the loose PCV and tightened all the hoses that had come lose, switched out the spark plugs for new ones, checked the spark (again, which worked fine), checked the flow of fuel (which also had good flow and seemed to work fine), I checked the ground connections that I could find, and started to replace any connections that looked like they might be an issue.

.... I keep hearing a million different suggestions to what the issue may be (or maybe it is just a million issues I am having). I have a feeling that it could be the vacuum, and I want to replace the 4 boots to the intake, but I heard it could also be faulty injectors... and the list goes on (all the old schoolers say I should take out the injectors and put in a carb... which I dont have time or money for).

Someone please help me, I will try and get photos of my engine up soon so it can be reviewed... I really love driving that van, but I'm near a wits end and I dont have a big bank account.

Thanks...
The D

[subter]

Ignition switch?
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1981 Westfalia

[reluctantartist]

First download this and study it. It has a trouble shooting section that may help.
http://www.thesamba.com/vw/archives/manuals/afc_fi_training_troubleshooting_manual.php

Do you have a vacuum gauge? A fuel pressure gauge is is also nice to have and both can be picked up at harbor freight.

Follow the trouble shooting section and see what you come up with. Do not start throwing random new parts at it hoping that fixes it. That gets expensive really quick.

Good luck.[/url]
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1982 Westy, 1974 412 Variant... Yes, Aircooled's are great! Oh and I do have modern computer controlled vehicles too, but I just don't care about them.

[rsxsr]

Welcome to Samba. It does not matter what vehicle it is, trying to troubleshoot electrical takes a guality repair manual like the Bentley and at a minimum a 12 volt test light. Otherwise you are just guessing. The ignition switches do fail and have lots of different symptoms. They are cheap and can be replaced by an amateur with minimal tools in less than half a day. So as recommended start there.

Now the bad news. Vanagons and small bank accounts are a bad match. To have one that is strong and reliable will take quite a bit of money. You don't need to fix it all at once, but you can expect to drop $10K into it over the next 5 years and that is if you do all the work yourself bringing it back to like new condition.
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1982 Diesel Vanagon Camper with ALH TDI.
1987 Syncro Tin Top. Organ Donor
2011 TDI Jetta Sportwagen.

[dfbland]

Well, I did replace the ignition switch for the heck of it, and it was a good thing that I did that, only a matter of time before that would of screwed up on me. But it didn't fix the problem (I understand that it may have been a long shot in the dark), it did however make things a bit more confusing.
Before the switch the engine actually would start when the battery was charged and would die as I let go of the key from the start position... but now the engine just sounds like it is struggling to make anything happen past the sounds of wanting to start, but not happening.

Ill look at the troubleshooting website you sent and see if I can identify the problem that way.

As for the small budget and the ownership of the Vanagon, I never knew the commitment I was getting myself into when I purchased this vehicle (it only cost me $2000 and ran perfectly when I got it, but had been sitting around for about 3 years), and now that I have I realize I have to get it running again no matter how... which means trying to catch and eliminate problems myself as I go.

Thanks for the help, I guess there is just so many issues it could be that I am going to be putting a lot of time into this.

[Wildthings]

For starters make sure the wiring harness is securely plugged into the AFM and then go over the engine one more time to see is any hoses have been knocked off.

The hiss you are hearing could just be your fuel pressure regulator doing its job.

[reluctantartist]

You should replace the four intake boots if they look ratty. All of the vacuum hoses should ne replaced of original. The throttle body seal may be bad as well. These are 30 yr old vehicles so all of the rubber is suspect. It was not meant to last that long. Do a search on vacuum leaks, there is a lot of good info on ways to track them down. The trouble shooting section on the AFC is very helpful
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1982 Westy, 1974 412 Variant... Yes, Aircooled's are great! Oh and I do have modern computer controlled vehicles too, but I just don't care about them.

[Mr Brown]

[dfbland]

I am just waiting on the boots and gaskets to come in, and I noticed that the Auxiliary Air Regulator's electrical connection was pulled out of the AAR, I am not sure if there has been a disconnection or how it actually happened (someone probably screwing around with the van when I wasn't looking...?) and I am wondering if this could be the main direct problem that I am experiencing... could the replacing of a AAR be what fixes my situation? Or is that a irrelevant for starting the engine?

As far as spending $10,000 over the course of 5-6 years... I don't mind seeing as I spend around that on skiing and surfing alone in half that time (and I save money on not paying for hotels/hostels).
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Slow on the way up the hill, fast on the way down.
-DB

[reluctantartist]

It sounds like a few problems going on. The current one may be the new ignition switch, do you still have the old one? I think there is a simple way to test of you do. The next thing is to make absolutely sure there are no vacuum leaks. I would also check temp 2 sender.i
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1982 Westy, 1974 412 Variant... Yes, Aircooled's are great! Oh and I do have modern computer controlled vehicles too, but I just don't care about them.

[dfbland]

I am actually suspecting the Temp 2 Sender as the problem, it makes a weird clunking noise whenever I turn the key and step on the ignition. I am also looking for any leaks (cant seem to find any).

I can see how the new ignition switch could be of concern, but at the same time, the old one looks so beat up and ready to fail, that I would be way to concerned with putting it back in.
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Slow on the way up the hill, fast on the way down.
-DB

[seanjenn]

I put a new ign. switch in one of my vans, less than 6 mos later it was junk. The terminals had come loose and the only way to start the van was to wriggle and twist on the wires. Put the old, OE switch back in and drove it that way for a few more months until I could get a proper switch, the ones from Van-Cafe are solid.

Don't you dare swap your FI for a carb! Some "old schoolers" are just too cro-magnon to deal with "new" technology. Besides that, the FI systems on these vans are pretty basic. I'd say if you're hearing a hissing/air leak sound, chase that one first. Besides intake boots and throttle body gasket, look into the brake master cylinder hose, from front to back.
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1984 Westy 2 Dubya D
1.9L 4spd


God thinks he's Eddy Merckx