new to me 1975 Super Beetle project

[plextor]

Took the fuel injectors to a local place to clean and test them. Good news is they all work and cleaning made a big difference! Excited to get these back in this weekend.

[Buggeee]

What a great service! I did not know that was available.
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1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[plextor]

[plextor]

[plextor]

An update after a while (where does the time go...)!

After a bunch of work, I've confirmed that fuel is flowing through the system using a new fuel pump, lines, pressure regulator, the works. Yippie!

Lately, I've been diagnosing no spark from the coil. This is my first time ever work with distributors and coils, so all new to me.

The regular diagnosis showed no spark coming out of the coil, so I eventually replaced the coil, the points, and the condenser. Still no spark! Following the diagnosis steps at http://www.nls.net/mp/volks/htm/spark.htm it looks like I'm not getting any current flow when the condenser is connected to the coil.

Looking closer at my distributor internals compared to others, besides looking kinda grimy, it looks like the advanced plate is stuck and that some part (I'm not sure what that little lobe part is called) is contacting the condenser terminal and that seems to be the source of my trouble. The ground strap to the advance plate is nasty but still a solid connection. For those that know more - does that sound right?

This is the 0231 176 044 distributor, with a dual vacuum advance. This car came with one of the vacuum advance lines disconnected, so I assume there was some trouble with it in the past.

I have a brand new Hot Spark 3BOS4U1 distributor with electronic ignition, which is supposed to be the right model for the 044 distributor. At this point, is it worth it for me to pull this old distributor out and rebuild it, or just put this new one in and give that a go?

[vamram]

Both - put in the HS one to see it will run, and rebuild the original solex to clear out the crud.
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Eventually, "we are what we pretend to be.’”
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!

[plextor]

Progress! Today I had actual combustion on engine start. A couple in a row even.

I was going methodically through the troubleshooting guide for the l-jetronic FI system after replacing the distributor and found that the double relay isn't 100%, so one of those is on order.

I also found that I still wasn't getting fuel pressure even after verifying everything on the new fuel lines, tank, pump, filter, etc. TL;DR I discovered that red/black wires on this car do not mean what I think they mean. 🤪 So some more time with the Bentley manual to make sure I understand the wiring and don't just assume.

But great news is, it tries to start and it's behaving the way I would expect right now. I need to get that new relay, make sure the timing is good again after installing the new distributor (first time doing it so I want to double, triple check), and then I should be g2g I think!

[finefettle]

I had user name heimlich from Texas rebuild my distributer . And it is perfect.
I would use refurbished original parts where you can. Keep up the good work..
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1979 Bug project

[plextor]

[plextor]

And... she lives! Today was first start after ~13 years of sitting.


Link


After this I got the timing and idle speed adjusted properly.

Beside the replacement delay, distributor, and all the other work I did, the last thing I had to do was connect the upper crankcase vent hose to the S-boot; if that wasn't connected, or closed, then the engine would not run for more than a couple ignitions. As you can tell, I do not have a correct fitting hose so that's the next project in the list!

[plextor]

I guess everything I've done so far:

• replace fuel pump, all rubber fuel lines, and fuel filter
  
• replace fuel tank, fuel float sensor, and hoses to filler neck
  
• replace fuel pressure regulator
  
• cleaned out hard fuel lines running through body
  
• removed and had all 5 fuel injectors professionally cleaned and tested
  
• replaced distributor with rebuilt model matching this engine (and new points, condenser, cap, rotor, etc. as part of that)
  
• replaced plug wires
  
• replaced coil
  
• found a new hose for the oil filler neck crankcase vent to the air filter (missing)
  
• found a new hose that doesn't fit! for the upper crankcase vent to the air filter
  
• replaced most of the vacuum lines (a few remaining that are in OK shape)
  
• various electrical connection replacements, fuses, etc.
  

[plextor]

Both the EGR vacuum line and the retard vacuum line to the dual vacuum distributor are not connected. I'd like to fix both of those as it doesn't seem like anything was wrong with either vacuum canister.

[MuzzcoVW]

[plextor]

[plextor]

Boy, with the engine running it sure is a lot easier to spot those exhaust leaks!

I've got a new muffler on order and put some exhaust paste on there for now. I'll likely remove the EGR filter and cap it off at the catalytic converter port rather than replacing it.

[finefettle]

Congrats on your success.
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1979 Bug project

[plextor]

yum!?

[plextor]

As detailed a bit more in https://www.thesamba.com/vw/forum/viewtopic.php?p=9862355 I had a problem with 2 of the cylinders not firing.

Turns out two fuel injectors were bad (even after the fancy cleaning job earlier in this thread), so I replaced all 4 and now its running great.

I think the cold start injector might also be troublesome so I'll test that one in the next set of projects.

I was able to get it on the road and drive it around the block a couple of times. It's a car again!


Link

[Buggeee]

What a great feeling! Congratulations!
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[plextor]

And a full walk-around now that it has been washed and driven a few miles. It is driving great!

Things that are up next:

• tires (and maybe wheels)
  
• figure out if cold start injector is actually working, and replace it if not
  
• replacing hard evap system lines and changing the charcoal in the canister
  
• replacing my janky oil breather hoses with something more permanent
  
• fixing interior panels where they've come unattached
  
• pulling the dash off and rewiring / replacing the fuse box and getting it mounted properly
  
• installing the OEM clock for this unit into the dash
  
• replacing the stereo with something less 90s
  
• figuring out why fan motor isn't working
  
• clean out all the air vents (yikes)
  
• replacing windshield washer bottle system with a 12v one
  
• replacing muffler and tail pipe
  
• maybe remove remainder of EGR system (right now filter and pipe have been removed and muffler pipe blocked)
  
• replacing various rubber grommets for wiring
  
• figuring out why bumper's rubber grommet isn't staying put
  
• cleaning/polishing bumpers!
  
• disc brake conversion
  

Link