When I messed with mine I discovered that getting the switch to function
consistently is more important than getting the precise gap.  I replaced the
switch and the plastic cam on my '85 about 2 1/2 years ago and had fits
trying to get the bugs worked out.  Finally chucked the feeler gauge back in
the tool box then used the Digi-tool (Thank you again Darrel) to tweek the
adjustment til the green light came on everytime I let the throttle off.
The end result was a good strong consistent idle with a gap well outside the
factory specs -- what the heck the engine is like 18 years old there's gotta
be some serious wear somewhere.  It has worked great ever since.

By the way, my van has a May '85 manufacture date and is equiped with the
dual function switch like the 2.1s.

Chuck
'85 Wolfsburg Westy - 'Roland the Road Buffalo'

on 9/29/03 5:03 PM, Automatic digest processor at LISTSERV@GERRY.VANAGON.COM
wrote:

> Date:    Mon, 29 Sep 2003 15:11:28 -0400
> From:    Eric Zeno <vw4x4@FYI.NET>
> Subject: Re: Throttle switch adjustment Dilemma finally Figured out!!!
>
> Have you replace the switch and plastic cam with the
> updated parts?  This may  help.
> Eric
>
> Robert Lilley wrote:
>
>> I finally understood Bentley and how to adjust the throttle switch...
>>
>> I have been adjusting the switch opening gap from closed to open until the
>> click and then measuring that gap and adjusting until I got the .002 to .004
>> gap.
>> I have continuous had problems with the engine cutting out when cold over the
>> past 5 years.  It would cut out for days then not cut out.  I have adjusted
>> various parts, adjusted timing, etc. And sometimes it would go away for
>> several
>> months.  I put in a new switch thinking there was a problem wit the original,
>> but have since put the original back in.  When you think you have solved it,
>> it would resurface.
>>
>> When I was reading it for the umpteenth time, I finally understood it as it
>> needs to click off at that gap WHEN CLOSING the throttle switch not when
>> opening it.
>>
>> What that means is that you have the feeler gauge between the throttle stop
>> and the adjusting screw and when you close the throttle it turns off WITH THE
>> FEELER gauge in place.  I set mine to be .003.  At .004 it does not turn off.
>> I had not had any problems with idling or cold cutoff.
>>
>> I had been doing it backward for a number of years.
>>
>>
>> If you need more details let me know...
>>
>> Robert
>>