Power problem w/ new 2.0 FI -- FIXED

[ScottK]

I recently installed my new 2.0 longblock, and have had serious power problems since day one (hard to get past 30mph or so on flat ground). I have searched the forums, read a bunch of posts, and cannot figure this thing out for some reason.

I have checked and rechecked for vacuum leaks, adjusted the AFM wiper arm slightly (was running very rich), adjusted valves first to .006 to let the hydraulic lifters pump up for a bit, now they are 1.5 turns preloaded. Compression test shows 140# plus on all 4 cylinders. I took out the plugs the other day to see if they showed anything, and this is what I see (left to right cylinders 1-4):

2 & 4 look very fouled and 1 & 3 look new. Mind you this engine only has about 15 miles total on it, not counting the few hours of running for troubleshooting.

When I removed the plugs in the pic, I replaced them with new Bosch W8CC's. Removed the Bosch plugs today and they look the same, 2/4 fouled, 1/3 good.

Any suggestions on where to look next?

Almost forgot, fuel pressure is 32 psi with vacuum hose connected, 38 psi disconnected. Cold start valve checks good, no leaking.

Thanks,

Scott

[USMCbug]

Looks like timing/distributor problems.
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65 Split Window Bus
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71 Super Beetle (current)

"When war does come, my advice is to draw the sword and throw away the
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[1975 Kombi]

You might want to pull the valve covers off and have someone turn the engine over to see if your getting full deflection of the rocker arms. Just to check if they are all moving.
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Brett

“He’s decieving you boy! Reach into his pocket and take what he’s got.” Mr. Crabbs.

75 Westy auto
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[JSMskater]

[busdaddy]

Any chance you have 1&3 wires mixed up?
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[ScottK]

I'm sure on the plug wires, but I'll check again. The distributor I've got is a used 205P, I don't know the true condition of it. Maybe that's the whole problem, I just don't have the cash to buy a new SVDA at the moment.

It seems to idle smoothly once it warms up (can't hardly keep it running for the first few minutes when cold) and the timing is @ 7.5 BTDC at idle, advances to 40+ when revved up with the can connected.

Thanks for the replies so far. I'll go back out in the morning and do some more checking. I've had this bus for 2 1/2 years now, I'm starting to get impatient with it!


Scott

[Bleyseng]

Check to see if all the injectors are spraying fuel, check to make sure all the plugs spark....if they all are you have the firing order mixed up.
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76 Porsche 914 2.1L L20c, 120hp Djet (sold)
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[germansupplyscott]

switch the injector wires bewteen 1 & 2 and 3 & 4, try this while the engine is running. this will tell you a few things about what is going on.
_________________
SL

[ScottK]

OK, so it's running on 2 cylinders. I removed the injector plugs, they are getting the firing pulse while cranking it over(verified with test light) but if I pull 1 or 3 with it running it makes no difference. If I pull 2 or 4, it dies.

The spark seems weak (yellow), but they are all getting spark.

Injectors have not been pulled out to check spray, but I did ohm out the coils on all 4, and they are good. Injectors were sent to Cruzin Performance this summer and were cleaned/refurbished so I assume they are spraying OK though I guess I should pull them and verify.

Seems to run fairly smooth for only running on 2 cylinders but that would sure explain the lack of power....

I'm at a loss here.

[USMCbug]

ScottK, are you getting spark at the spark plugs? The injectors may be fine but not getting anything to ignite the fuel.
_________________
72 Super Beetle
73 Standard Beetle
79 Baywindow Bus
65 Split Window Bus
79 Baywindow Bus
71 Super Beetle (current)

"When war does come, my advice is to draw the sword and throw away the
scabbard."
- General Thomas "Stonewall" Jackson

[ScottK]

Yeah, I used a spare plug I had and put it in each plug wire. Cranked it over on each wire and got a weak spark. I also used my timing light on each wire with them connected to the installed plugs, and the light fires on each wire. The spark coming directly out of the coil is yellowish also, but it is generating a bit of spark.

This is probably going to end up being something simple, and I will feel like more of a moron than I already do.

Thanks again for the info so far.

Scott

[germansupplyscott]

try switching the injector wires between 1&2 and 3&4.
_________________
SL

[davis911s]

Just to confirm that you retraced the spark plug wires and they are all hooked up correct and in the right order on the cap?

If plugs 1 and 3 are getting spark and fuel they should not look new. That is the weirdest part.

Pull out each injector and test to see if they are spraying. (place in a jar) I am betting you are getting no fuel to those two injectors. Something unhooked or plugged. Pull off some fuel lines and blow them out.

Shawn
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[ScottK]

I'll swap the connectors in the morning (at work tonight). Depending on the results of that, I'll pull 1 & 3 injectors to see if they are indeed spraying fuel.

Plug wires checked and rechecked for proper order. Will posts results tomorrow morning. Thanks again guys!

Scott

[dweller]

[1975 Kombi]

Check the engine grounds also.
_________________
Brett

“He’s decieving you boy! Reach into his pocket and take what he’s got.” Mr. Crabbs.

75 Westy auto
03 Jetta TDI
71 SB
74 Westy
Licensed pilot (single engine land VFR)
--
Rust In Pieces: 72 Bug, 73 Bug, 81 Rabbit LS D 2D, 83 Rabbit D 2D, 84 Jetta TD GL, 85 Jetta D, 68 Z28 RS 302, 91 Passat 16v

[busdaddy]

[ScottK]

Swapped connectors between 1/3 and 2/4, no change. Going out to pull injectors now.

[Jody '71]

This all sounds electrically related. Weak spark and a questionable distributor, not to mention the coil's output? Could be something simple like the dizzy may have timing scatter. Bad timing gear? Or a bad distributor cap? Do the clean plugs smell like fuel when you pull them out or are they bone dry? The suggestion about checking the fuel rail for clogs is a good one. The really foulded 2 and 4 and clean 1 and 3 plugs has to be electrical somewhere, unless the suspected injectors are malfunctioning.
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'66 Beetle
2011 Hyundai Elantra Touring

[ScottK]

Injector 3 is not spraying fuel, have not pulled the 1/2 side yet but I would assume 1 is not spraying either. I did not have any help, so I had to just wrap a rag around the injectors and go up front to turn it over several times. The rag around #4 was wet, #3 was dry. I guess I've got 2 bad injectors even though they were recently cleaned and tested.