Buddy the wolf's 81 aircooled

[BuddyTheWolf]

I have an early 81 aircooled I saved from the junkyard. I got the engine running but when I try to put it into gear the engine dies.

Suspecting a vacuum leak I replaced all rotten vacuum hoses and the intake manifold gaskets, I also blocked off the EGR port and removed the valve. I also replaced plugs and wires, didn't make much difference. Fuel lines and pump are new as well.

Any ideas on what could be happening? I'm hoping it's not a transmission issue. I don't think it is, I actually got it to drive a few feet a few days ago in 1st gear, but it's gone back to dying immediately when put into gear. Clutch seems to be working fine (engine dies when clutch let out) Could a faulty airflow meter or injectors cause this? Engine seems to rev up fine in neutral. Wheel hubs aren't locked up either.

Sorry for the infodump, here's a photo of her moments before being saved from death row

Thanks!

[MarkWard]

It rolls forwards and backwards in neutral? What if you try backing? Same issue? I recall a van that had a harness problem that when the engine shifted would quit. You need to figure out if it’s electrical or fuel. A timing light and a fuel pressure gauge would get you closer.

[BuddyTheWolf]

Same issue either in 1st or reverse, it lurches a bit and dies.

I found out one of my injectors started leaking fuel out the side of the pintle cap when the system is pressurized, so that will need to be taken care of, don't think that is my issue though it just started leaking. Will get a fuel pressure gauge to make sure that part of the system is happy and I'll check the timing as well

[Ahwahnee]

[BuddyTheWolf]

I did engage the parking brake on the hill I parked it on so possibly, I will try to jack it up and check, tricky on the hill though

[MarkWard]

So, you can start it easily and it will idle all day? Where did you find a hill in Florida and choose that as your service spot? I saw another thread where you purchased this from a junkyard. I’d say, you have a long hill ahead to have a reliable daily driver, but good for you.

[BuddyTheWolf]

Our house is built on a slight hill for the septic system. I'm able to push it so I don't think the hubs are locked up. Had to move it out of the driveway

[Wildthings]

When I fire up a rig that has been out of service for more than a few months, I always add fuel injection cleaner to the fuel and will often add synthetic oil to the fuel as well at a 100:1 ratio to keep the ethanol gum from causing the injector pintles and valves stems to stick.

[BuddyTheWolf]

After dropping the old broken tank it is full of powdered/flaky rust. I mean pounds and pounds of it. Surprised the injectors worked at all. Gonna just replace them with better 4 hole ones. Got a big spin on 10 micron fuel filter and housing I will install under the van too for max flow

Would injectors for a waterboxer work? I see some are advertised as 1.9-2.1 so logically should dispense the correct amount of fuel for a 2.0 engine, or are they electrically different? I know about Injector Rehab's replacement rail but it's out of my budget for now

Edit: looking at the bentley manual it seems the WBX injectors are a higher resistance, I'm thinking removing the resistor box would work, since that's what Injector Rehab's EV14 upgrade recommends for their aircooled kit, it might work on the older waterboxer injectors as well

[Wildthings]

[BuddyTheWolf]

I figured it out, front right bearing keeps seizing from rust. Cleaned both bearings and lubed with Redline grease (left bearing looks almost new so will replace right bearing eventually, it works fine at the moment but it is pitted)

[Nitramrebrab72]

Rusty fuel tanks leave flakes of rust in the fuel pump's internal strainer restricting fuel flow, giving those exact symptoms , remove the pump and with the fuel pumps 12mm entry port facing downwards tap it against a piece of wood placed on a bench that combined with a dentist pick type of tool (or a steel wire with hook on the end) prying at the stuck in flakes. You will be surprised by what will drop out. You could also open the pump if you have the experience doing that, but tapping normally works fine if you are not looking for perfection .The fuel tank usually rust on the top central low part where the large diameter air tube runs due to it retaining leaves and dirt. Once you have cleaned the pump you will need to fit a strainer before the pump as it will do the same within a few thousand miles.

The Shurflo strainer is great tried and tested high quality thick nylon you have a choice of different diameters and can be fitted either way regardless of the flow arrow. It is sold as a water strainer but works fine with petrol or E85 it can be easily cleaned and has a see through bowl.

[MarkWard]

[BuddyTheWolf]

Ok, not 100% solved. Still stalling but rolls a bit farther. Wheels spin fine when rear jacked up and put into gear.

The engine can rev up to high RPMs with no issue, just load on it causes it to stall. Gonna replace the injectors since one was leaking out the side anyway.

Oh, and I have a new fuel tank and pump, I have a pre-filter screen for the pump as well.

[Wildthings]

What happens to your fuel pressure when you put the engine under load? It should actually go up as the manifold vacuum drops. If it goes down you have a supply problem.

[Nitramrebrab72]

Standard make aftermarket injectors for the type 4 engine.
It could be the injectors stuck closed but dribbling enough fuel to idle.
You could also check the AFM is functioning correctly and it's voltage is going up and down as you accelerate.

[Wildthings]

An AFM that isn't plugged in may cause those symptoms.

[BuddyTheWolf]

I adapted some 6 hole 200cc fuel injectors for a Honda and bypassed the resistor pack. Also redid the fuel system with a prefilter screen and the large spin-on 10micron filter.

Engine runs a lot better (before it had a slight misfire) but the issue persists. I think the engine just has low compression. Getting a compression tester and timing light next.

[BuddyTheWolf]

She moves! I think the bottle of engine restore helped alot. We had some fun offroading in the yard (until one of the wheels fell off )

[jlrftype7]