Clutch replaced in Baja, now loss of power, fuel starvation?

[AzPutt]

So, to make a long story short, I recently traveled to Baja (from Tucson, Az) for a month, driving to the end of the peninsula and back. The van (1986 Westy) drove great until (trying to climb a washed out mountain road) I burned out the clutch, stranding myself in the middle of nowhere – and 2days before I had to be back in Arizona! After spending the night and with a bit of luck (full story coming soon), I made it to the small town of La Valle de La Trinidad (about an hour or so south east of Ensenada). There, I found a mechanic who specialized in VWs. He was great. He had the engine out and the clutch replaced in 6 hours and it only cost me $200! He also let me watch the whole process.

In any case, everything seemed fine, until I started driving north. After about 20 minutes of highway driving, suddenly the van lost power, (as if starved for fuel). I continued driving (didn’t stop or shut the van off) and after a couple minutes power returned. I was able to drive the 9 hours it took to get back to Tucson, but the problem persisted the whole way. A couple times each hour, the van would suddenly lose power and then regain it after a few seconds to a minute. I noticed that if I jammed on the gas/accelerator it seemed to get going again in less time. I also noticed that the turn signals stopped working…

To make it easy, here is a list of the symptoms:
Loss of power after a few minutes of driving (feels like it is starved for fuel)
Power kicks back in without stopping or turning off van
Van doesn’t seem to buck with loss of power (just slows significantly)
No turn signals ( not sure if related)

So, here is a list of things that I have repaired/replaced in the last few months:
Fuel pump replaced (refurbished) – I hear the fuel pump turn on
Fuel pump relays replaced
Distributor replaced (after I had similar symptoms due to bad hall sender connection)
new spark plugs
grounds have been cleaned – not corroded
Temp II sensor replaced
O2 sensor replaced with o2 sensor from another vanagon (didn't test it - don't know how
I think thats it...

Any ideas as to what the problem could be? Vanagon syndrome?
Could it be dirty fuel injectors?
The problem started after the engine was dropped to install the clutch. What could have been changed/damaged when the engine was pulled out? Also, what could cause the turn signals to become defective after this?

If you have any ideas, please feel free to list what I should check, how I can check it and in what order I should check things?
Big thanks!
I love this vehicle and I’m looking to go on another trip soon, so I’d like to work this out!

[Ahwahnee]

One possibility is a partially blocked catalytic converter. That 'washed out mountain road' is just the sort of thing to deliver the final coup de grace to a converter that is about to go (I did mine in on the Puerto Blanco Road).

Could be other stuff of course, just a suggestion for an area you didn't mention.

[0to60in6min]

I'd suggest to begin, check all electrical connectors , including ground connectors, and pay attention to the one inside a plastic casing. You may hear a click but the contact may NOT come thru (I learned it the hard way). All of them no exception ! !

Since the engine was dropped for the clutch work some of the connectors may be not re-connected properly or not at all..

good luck and let us know

[AzPutt]

Thanks for the tips.

I don't think it's the Cat, as I replaced it prior to Baja and it didn't look blocked, so... ?

In any case, I'll check all the grounds and scratch my head some more. It is starting to cool down here in Tucson, which will make it much easier to do van troubleshooting (without sweat dripping into the eyes).

I'll keep you posted.