

| Subject: | Re: 1991 Vanagon sputters and blows black smoke on highway. |
| From: | Bill Marshall |
| Date: | Thu, 3 Jul 2003 10:17:21 EDT |
During my sputter/smoke escapades, it randomly happened when the engine was warm. After a long time of trying everything else, a guy with a PC in his shop pinpointed which ground was bad. Yep, the invisible one on the left head. Weird thing about bad electrical connections -- they come and go under the strangest conditions. My ground made enough contact on a cold engine to work, but as it warmed up something expanded or moved, or some chemical property changed, then no juice would flow. I'll bet something inside the engine bay is getting wet under the high-pressure spray and shorting out (is your ECU in the rear pillar?), or maybe the water is cooling off a connector and causing it to contract away from the connection. Obviously, the only thing to do is take apart every single connection and terminal on/in the van, clean it, and coat it with dielectric grease before cranking it down tight. Then test with a quality voltmeter. That should only take a month or two. ;-) Bill Marshall 85 GL Tiico "Pandora's Box" Aurora, IL
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