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Sat Apr 19, 2025 3:07 pm

Hey all -

Helping a buddy get his 77 Westfalia back on the road. It's got the 2.0 flat 4 w/injection, which is totally new to me. I've only worked on the 1600, but a lot.
He hasn't maintained it much, so I did a full tuneup, and it barely fired, and would idle okay but a little rough, and choke if you give it gas. I could smell fuel, so don't think it's necessarily a fuel issue. But I know zero about the FI.

Any ideas on what to check next? Or how to check the injection system? Any help is much appreciated!

RNY

Sat Apr 19, 2025 3:41 pm

Welcome!
There's no magic answer here, more testing is required.
If you could smell fuel and there wasn't any leaks the first thing to inspect is the temp sensor in the head beside the #3 intake pipe flange, is it tight in it's threads and making good contact?, is the wire connected to the single lead coming from the FI harness?, does unplugging it make it run differently?, does grounding the harness lead to the block make it run differently?

I mention leaks because FI systems run at elevated pressure with high flow rates, any rubber hose in the system should be replaced if you don't know it's age, if one lets go the fire will be spectacular. Use FI rated hose, preferably SAE J30R9 or better, and proper ABA style hose clamps, no cheapo hose and worm clamps, that's almost as scary as old hoses.

Here's a manual on the system: https://www.thesamba.com/vw/archives/manuals/afc_fi_training_troubleshooting_manual.php

Sat Apr 19, 2025 5:05 pm

how old is the fuel and how old are the injector seals? Did you do a cylinder balance test to see if all the cylinders are firing?

Sat Apr 19, 2025 5:36 pm

Hey guys, I appreciate the responses, but talk about a stupid question...I don't see anywhere to RE to your responses. How do I do this?

Sat Apr 19, 2025 5:52 pm

hit the quote button to reply to a specific post.

hit the post reply for a general reply.

i hit the post reply.

Sat Apr 19, 2025 6:05 pm

dodger tom wrote: hit the quote button to reply to a specific post.

hit the post reply for a general reply.

i hit the post reply.

Ah! Quote...got it thanks.

Sat Apr 19, 2025 6:17 pm

busdaddy wrote: Welcome!
There's no magic answer here, more testing is required.
If you could smell fuel and there wasn't any leaks the first thing to inspect is the temp sensor in the head beside the #3 intake pipe flange, is it tight in it's threads and making good contact?, is the wire connected to the single lead coming from the FI harness?, does unplugging it make it run differently?, does grounding the harness lead to the block make it run differently?

I mention leaks because FI systems run at elevated pressure with high flow rates, any rubber hose in the system should be replaced if you don't know it's age, if one lets go the fire will be spectacular. Use FI rated hose, preferably SAE J30R9 or better, and proper ABA style hose clamps, no cheapo hose and worm clamps, that's almost as scary as old hoses.

Here's a manual on the system: https://www.thesamba.com/vw/archives/manuals/afc_fi_training_troubleshooting_manual.php

Many thanks for the info! I guess I need to learn (whether I like it or not) a little more about the FI system. Thanks for the manual too.