1991 Multivan TDI build

[Multiman mv]

I just wanted to clarify for anyone out there contemplating a FAS conversion that my recent woes have nothing to do with the conversion itself. I’ve narrowed it down to a fueling issue and I’m waiting for a fuel filter to arrive so that I can replace it. I live on an island where the quality of diesel fuel can sometimes be questionable so it is an issue I need to be aware of in the future. Why my mechanic (soon to be former mechanic) couldn’t figure this issue out is beyond me. The fuel filter was one of the first things I mentioned to him to check and he never looked into it. It led to many many miles of frustration. Again, this issue has nothing to do with my conversion and my tdi has performed beautifully to date, serving us very well. The reliability has been incredible and I wouldn’t hesitate to drive this van any where in the country (after I replace the fuel filter of course.)

So, going forward, vagcom is in my future and I plan on looking for a mechanic who will be more proactive and try to find someone who is willing to dig much deeper than just scratching the surface. For anyone contemplating any conversion, make sure you at the least have good mechanical support in case the inevitable maintenance issue pops up.

[Farfromslow]

Glad you got it figured

[AndyBees]

Well, I doubt the issue you've been experiencing has anything to do with the conversion itself.

I'm going to throw this out and you can decide it's worth.

I've been driving VW diesels since January, 1980 rolling up well over one million miles. During that first year, I would drain a little fuel out the drain on the bottom of the filter to expel water. Never did I find more than a drop or two of water. So, I quit that practice and have never checked for water since in any of my VW diesels. I've also dissected a few filters to see what's inside. I found nothing to be alarmed about.

During the latter years of my career I was driving 36k miles per year in my 2000 Jetta TDI. I changed the fuel filter once per year in late November/early December so it would be fresh for the winter months...never a fuel filter issue. I purchase fuel where it is the cheapest regardless of name brand. I've purchased fuel in every state except Hawaii and pretty much all over central and western Canada. Never have I experienced a bad fuel incident. Sure, I may have got some bad fuel from time to time but I suspect the filters have been effective in their purpose.

Hardly believable, but my brother never changed the original fuel filter in his 2001 Jetta TDI until just shy of 171k miles and never experienced any problems.

My point is the EO fuel filters do an impressive job of filtering.

So, in your case, I hope the problem is as simple as a bad batch of fuel that has plugged the filter.

Just curious, does the FAS set-up include a lift pump? If so, where is it located? The cars with the PD engine have a lift pump in the fuel tank. When that lift pump quits operating the engine becomes a hard starter. However, once it starts there's no ill effect on performance.
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'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003.

[snwbrdr435]

[AndyBees]

[crazyvwvanman]

Some came with metal, some with plastic fuel tanks.
I've had quite a few with factory plastic tanks and never had a rusty tank in one of those. A few gallons larger as well.


Mark

[AndyBees]

[Steve Arndt]

All Syncro have plastic tank for what that's worth.
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Steve
Steve's 87 Syncro project

[crazyvwvanman]

Yes, those would be the ones with stock plastic tanks, and a few gallons larger.

Mark

[Multiman mv]

I wanted to report that I picked the van up from the mechanic (same mechanic I’ve been using) and everything is sorted out. The Burley 930 kit looks rugged as hell and the occasional clicking of the drivers side cv is gone.

While the van was in the sick bay, I also had them change the transmission fluid. I am going to stick with changing the fluid at 20,000 intervals instead of the recommended 30,000 intervals in an attempt to baby this transmission. Most importantly, I also had them change the fuel filter and I’m happy to report that the lack of power and hesitation is gone. The van is back to its powerful self. It feels exactly like it did when I picked it up from Fas. Unfortunately, the mechanic threw the original fuel filter out after replacing it. I had requested that he keep it so that I could do a little forensic work. I wanted to cut it open to see what the offending matter was inside. I don’t think it was rust as my tank is in great shape. I’m sure it was a combo of bad fuel and maybe a little residual sediment from my tank.

I’ve got to say a big thank you to Samba member Steve from Marion (essjayarr) for suggesting a fuel delivery issue when he came and test drove the van. It was one of the things I had suspected but his instincts were spot on. Jon from Fas had also mentioned this as a possible cause of the hesitation and lack of power early on. It’s unfortunate that my mechanic didn’t listen to the suggestion to check the rate of fuel months ago. It would have saved me a lot of trouble and we would have made our trip to Nova Scotia.

I finally received my vcds mobile device yesterday and was able to scan for codes and found a P0301 (misfire of cylinder 1.) It took me a while to figure out how to force clear the code and rescan. I did clear the code and rescanned and found no pending codes. Everything seems to be running beautifully. I think when i tried to drain a little water out of the original fuel filter, I failed to properly re-prime the system and I experienced a little rough running for a few seconds afterwards due to a lean fuel condition and this is when cylinder one misfired. The misfire could also have happened during times of hesitation in 3rd and 4th gear though it never ran that rough, nor belched smoke etc. Hopefully no damage was done and I can take the entire situation as a learning experience. I’m looking forward to learning more about my van through vcds. Interestingly, the scan gauge has never picked up a code. I’m not sure why it hasn’t but now that I have vcds I’ll primarily use the scan gauge to monitor certain functions like coolant temperature, alternator output or battery voltage, avg mpg and mph

Again, I can not say enough about Jon and Chris up at Fas. They have been so readily available to help troubleshoot and offer assistance. They really didn’t need to help me figure out something as simple as a clogged fuel filter but they were very helpful. That goes a very long way with me. There aren’t many businesses out there that offer such support. Those guys deserve a huge thank you.

For anyone contemplating a FAS conversion, you will be beyond satisfied with their program and support. For anyone seriously considering a Fas conversion, please don’t hesitate to send me a pm. I’d be happy to give you my phone number and discuss the conversion and answer any questions that you may have.

[DuncanS]

Beautiful and congratulations on the finest yacht on the Vineyard.

[Multiman mv]

[Multiman mv]

A few more photos from the Burley 930 install.

[Multiman mv]

Great to have the van back so that we can use it for what it does best - family surf days at one of our local beaches. My five year old son Willie is fully riding waves, standing up, surfing. For me, that’s like most dads watching their kid hit a home run. So proud of him, fearless but with a healthy respect for the ocean and a natural talent and desire for riding waves. Here we are about to suit up and hit the surf. My daughter Charlotte is about to head upstairs to the loft or her “tree fort on wheels,” to play with one of her dolls in a room with a view of the ocean. This van has become one of the best babysitters in town!

[Multiman mv]

I’ve had the classic “lazy battery light” situation lately so I bought the gowesty “Alternator charge initiation kit” and it seems to have fixed the issue.

Before I installed the fix, the “battery light” would stay on until I revved the engine. If I didn’t rev the engine the light would stay on and my scan gauge would indicate the alternator putting out a voltage starting around 12.1 and then slowly rise until it reached the normal 14.1 range. The light would remain on even after the voltage climbed past 14. If I turned the vehicle off and back on, the light would go off and the charging voltage would immediately be around 14 volts. Apparently the issue is due to an increase in the resistance of the alternator excitement circuit or the result of adding accessories that draw from this circuit, like my auxiliary battery relay. The gowesty fix seems to have cured the issue (which really wasn’t much of an issue just an occasional inconvenience.) if anyone has any experience with this fix or any reason not use it, please let me know. I think it should be fine as all the gowesty fix is doing is “exciting” the alternator charging circuit immediately upon start up and allowing the alternator to charge right away.

[Zeitgeist 13]

Do you have any close up shots of the FAS transmission mount? I'm intrigued with their design, and think that approach might help address my TDI vibration issues.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[Multiman mv]

It’s hard to get a shot of it. I think FAS offers them up for sale but I realize you probably want to fabricate your own version. Maybe the next time it’s up on a lift I could get s better shot of it. I hope I’m not giving away any proprietary secrets or intellectual property. I’m sure FAS would be in full support of a guy fabricating something for himself. Hope this helps.

Basically the plate that bolts to the transmission is mounted to the two flanking mounts and the section that supports the mounts is bolted to the frame. It’s not unlike a mount I’ve seen here on the Samba that someone else fabricated though I can’t seem to find which thread it was posted in.

[Zeitgeist 13]

Thanks, that's perfect! Since my trans sits down and rearward, I couldn't use their system, so fabricating is my only option.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[DuncanS]

Whoa--Not so fast Zeitgeist--You think you can pass off a quickie comment--"Since my trans sit down and rearward..." and expect to no one to notice and wonder what kind of amazing project you have going? Fuggedaboudit. I know it's OT, but since Nick's thread is more of a wonderful blog than an actual how-to, perhaps we could digress for just a couple of posts--Nick's permission, of course.

[Multiman mv]