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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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 Posted: Fri Mar 19, 2021 5:03 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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| djkeev wrote: |
What is in his transferred engine that is causing this running issue?
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it's a head scratcher. it's probably these injectors you gave me. 
_________________
1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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djkeev
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Joined: September 30, 2007
Posts: 32561
Location: Reading Pennsylvania
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DanHoug
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Joined: December 05, 2016
Posts: 4751
Location: Bemidji, MN
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| Posted: Fri Mar 19, 2021 5:49 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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| dabaron wrote: |
| djkeev wrote: |
What is in his transferred engine that is causing this running issue?
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it's a head scratcher. it's probably these injectors you gave me. |
i had some spare injectors i'd rebuilt lock up while sitting on the shelf because i'd left them with gasoline inside. i now purge them with compressed air and a shot of WD40.
but the super wet #1 is what bothers me in this whole deal... it's hard for an injector to over squirt the pintle/hole quantity. they can have pattern anomolies, including a nearly perfect pinpoint stream which MAY do that but remember it squirts into the intake manifold just by the valve, it usually burns but not optimally. so i'm still thinking a spark issue. again, not telling you what to do but were it mine i'd:
- look at the spray patterns. best done by putting the nozzles in clear jars and cranking with a remote switch. you're not really doing a volume test but just looking for consistent spray patterns across all 4.
- pull off the RF shield on the dist cap, bin it, and clean cap well. pull the dist cap off and see if there's anything odd inside. if you have the pin style cap, make sure the rotor matches. Bosch 04170 VW 123 433 2350 is correct for the pin cap.
- at least ohm out the plug wires checking for 5k resistance. but a bad wire can also bleed off spark under load through the insulation to a contact point on the block. i've gone to a very high quality magnetic suppression wire with a thick silicone jacket. love 'em. makes me feel all warm and snuggly that my spark is going where i tell it to.
- i would substitute a known good AFM. it so odd that it starts running bad when connected. usually the ECU can correct mixture, especially at idle.
- i'd substitute a known good ECU because we ALWAYS think it is the ECU despite that frequently it is some other simpler issue.
- and as i keep harping, O2 sensors are tune up items. change it. same with Temp II sensors.
this is the perfect situation where an old school ignition scope would be helpful. not only does it reveal ignition issues, it provides a window into the combustion process as well. hard to find now a days except, as Skills would say, in the Polident and Depends crowd. twerp. 
_________________
-dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
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djkeev
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Joined: September 30, 2007
Posts: 32561
Location: Reading Pennsylvania
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djkeev
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Sat Mar 20, 2021 12:29 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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yesterday after work i removed the "Dave injectors" and put in the "Westy injectors" - it would not start. they would not flow. i put the "Dave injectors" back in and they aren't flowing very well.
i made sure to not put them back in the same spot - #1 to #4, #2 to #3, #3 to #2, #4 to #1. the rough running has changed in nature. this leads me to believe it is injectors.
this morning i spent 5 whole minutes at the Post Office. i sent out the original tin top, the original Westy, and Dave's donor engine injectors to Mr Injector in Idaho (who da hoe?). the plan is to get two sets back that are working perfectly.
i also ordered a new set of NGK plugs. i expect the injectors to arrive in 10-12 days.
when Dave comes over, we will rule out the AFM and plug wires. right Dave?
_________________
1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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dabaron
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Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Thu Apr 08, 2021 5:43 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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i sent out three sets of Bosch injectors to Mr. Injector. i was not sure if all 12 injectors had good cores, i was hoping for at least 1 working set. Mr injector let me know all 12 injectors were good and they cleaned up great. after a week long delay in shipping from the USPS, the package arrived. Ian, our USPS letter carrier is a fan of my Vanagon projects and made a special trip to drop off the package.
to say the injectors are well packed is an understatement. each set of injectors is bundled together and each injector is in a sealed bag with the needed rubber seal and retainer. they look great, but what needed done?
these two reports tell the story - 8 of the injectors were clogged, two were sorta clogged, and two were not terrible.
the injector swap went quickly, and with the system primed and no leaks found, it was time to start the engine.
the WBX started easily and idled smooth and even. i let it idle for a few minutes and the engine continued to run smooth. i took the Westy for a drive and it felt great. i saw Ian was still out delivering mail and drove up the block to meet him. he saw me coming and walked out to meet me sporting a massive smile. he said it sounded way better and was excited when i told him it was running great. he was having a tough day and said seeing the Westy coming up the street helped make it better.
i'm not sure what to do with the GP Sorenson injectors i removed from the engine. since i have two sets of spare Bosch, i don't NEED to send them to Mr Injector, but it would be interesting to see a report on them.
it feels great to have the WBX running correctly, it's been a long time coming. i should have sent the injectors out a year ago and should have known to replace the gas tank when i put the engine in the Westy. live and learn.
i'm very happy with the new heads and clearly the injectors were the final piece of the puzzle to make me a happy camper.
_________________
1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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dobryan
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Joined: March 24, 2006
Posts: 16494
Location: Brookeville, MD
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djkeev
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Joined: September 30, 2007
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Location: Reading Pennsylvania
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Sun Apr 11, 2021 3:34 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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i've logged 200 miles with the injectors and so far so good. today's trip to a far off Walmart was as uneventful as a drive can be, which is great.
these are the remaining "major projects" in order of importance:
overhaul suspension (already paid for)
change out headlights for e-codes, add DRL ($450)
new door cards - add power window relays and relocate switches ($400)
fix failed seam on rear left panel and deal with rusty front ($500+)
hammer out crushed rear right wheel arch and add terrawagen fender flares to hide the sins ($500)
maybe get the a/c working, maybe ($1000+)
_________________
1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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bobhill8
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Joined: June 09, 2017
Posts: 736
Location: MA
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| Posted: Sun Apr 11, 2021 5:35 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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Nicely done! Time to hit the road before something gets clogged.
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1986 Westy
1971 Squareback |
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Tue Apr 27, 2021 11:23 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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after having another heart skipping oil light incident after a few hours of highway driving, i decided it was time to spend the money for oil pressure and temp gauges.
here is everything prepped. well almost, i removed most of the teflon tape from the temp sender before install. reading the instructions sometimes is helpful.
all the things installed. now to run the sender wires and get power to the gauges.
i asked Dave where he pulled his power, there is an open keyed power source readily available, no hackery required. the slot with the blue spade terminal now supplies power to the gauge cluster. that was easy.
here is the super fancy gauge cluster installed. job done!
well fine, i should make it look nice, right?
is that better? i went for the "easy" to install T3 Technique pod. um... it came with nylock nuts instead of the wingnuts in the product description. ouch. i had to pull the stereo to get my hand in there with a 10mm deep socket and grip adapter. i'd imagine the wingnuts might loosen over time and we can't have that.
i have a replacement dash pad that is in perfect condition. i guess i can leave that in the dining room until i feel inspired to rip this all out.
of course the oil temp sender failed during the first drive with it. i thought VDO was quality, guess not. replacement on the way.
_________________
1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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dabaron
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Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Tue Apr 27, 2021 11:34 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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i love when packages arrive. today it's the part to fix the passenger visor.
after cleaning up tape residue and what looks like ancient Goo adhesive (anyone remember that?), the replacement swivel joint clicked into place.
job sorted. almost. i still have to deal with the vanity mirror light wiring, the connector was cut off the mirror for some reason. maybe one day when i'm bored i'll get to it.
_________________
1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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djkeev
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Joined: September 30, 2007
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Wed May 05, 2021 8:15 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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things are afoot. the dining room is going to be emptier real soon.
_________________
1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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dabaron
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Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Wed May 19, 2021 11:23 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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tired of tripping over the boxes of new bushings, springs, and shocks in the dining room, i decided i should install them.
parts to install: Schwenk springs, Bilstein HD shocks, bushing kit from Burley, Febi lower ball joint and tie rod ends, and Lemforder upper ball joint. i also picked up steering rack boots and shock hardware.
the passenger radius rod was clanking away, the UCA bushings squeaked, and the shocks were just shot.
after a bunch hours, the front suspension was removed. i had to order a few parts so i took the weekend off to go kayaking and hiking. i missed the Westy, it's way better of an outdoor support vehicle than my Subaru Outback.
both shocks needed to be cut out. that took the most time in pulling the suspension apart.
everything removed. the rust is sleeping, i swear. the LCA bushings were no match for the floor press i picked up.
cleaned and painted, looking way better. the one steering knuckle is from France, it consumed mass quantities.
i rented a ball joint tool set and used the collars to press the bad lower ball joint out and the new one in. again the floor press made easy work of this.
i thought i bent an upper control arm trying to get a bushing out. yes i cut the weld. i finally got all four bushings out and then came to the conclusion that the UCA was already bent. that part from France might ave been a replacement from a crash a PO had at some point but they left the UCA.
i replaced both UCAs with repros ordered from Van Cafe. the floor press made quick work of the four bushings.
no need for a spring compressor if the radius rod is removed.
i ordered a pair of tie rod ends yesterday after discovering the pair i had weren't for a Vanagon. they arrived this morning and i tossed them on, both sides are now complete. i'll do a final torque check and then install new rotors with new bearings.
tomorrow i'll replace the rear springs and shocks, the bushings will have to wait. i'll also replace the speedo cable, this one is mangled at the end.
lots of work but worth the effort.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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Jake de Villiers
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Joined: October 24, 2007
Posts: 5911
Location: Tsawwassen, BC
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dabaron
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Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Fri May 21, 2021 6:51 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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| Jake de Villiers wrote: |
| That looks really good!!! |
thanks Jake. it was a bunch of work, but worth it.
yesterday WE finished the install. my son helped install the new speedo cable, rotors, the caliper hangers and calipers.
the helper about to help
fancy!
the camber and toe-in need adjusting, i'll see what i can do to get them closer so we can go for a long drive.
the new speedo cable is making a clicking noise, but the speedo is showing the proper MPH under 30 so there is that...
_________________
1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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bobhill8
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Joined: June 09, 2017
Posts: 736
Location: MA
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| Posted: Fri May 21, 2021 7:13 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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Nice progress and great to have a helper!
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1986 Westy
1971 Squareback |
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dabaron
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Joined: June 21, 2018
Posts: 2559
Location: Philly, mang
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| Posted: Fri May 21, 2021 9:30 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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| bobhill8 wrote: |
| Nice progress and great to have a helper! |
very nice to have a helper, haven't had him around in over a year!
i decided to drop the Westy off at a shop to do the front end alignment... the tech was super excited when he saw me roll in. he asked when i was putting a Subie in it.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo
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