Make sure the intake manifold gaskets on the heads are lined up properly.
They can suck air if they slipped while attaching the manifold.  Mine did
and the engine ran like CRAP as well.  Also, did you buy new OEM ignition
wires?  Very important.  Spark plug gaps set properly?  Ignition sequence is
1-4-3-2.  Put the #1 (Right Front as you look at the engine thru the back
hatch) cylinder on TDC of the compression stroke and remove the distributor
cap to see if it is pointing to the wire that goes to #1 cylinder.  The
rotor will point to 4 then 3 then 2 as it goes around.  Make sure the wires
match the cylinders in that order.
TEMiller
----- Original Message -----
From: "Mark Seifert" <theburnvictims@HOTMAIL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, April 20, 2004 1:08 AM
Subject: rebuilt 2.1 runs like crap - can't figure it out

> I just rebuilt my 2.1 waterboxer and put it back in my van. I got it
> running, but it's not doing too well. First problem I had was the firing
> order. Got that figured out. I think I put the distributor drive shaft in
> wrong, but from what I understand, that doesn't matter because you can
turn
> the distributor any way to compensate. Valves were clattering a lot
> considering all the lifters are new. so I re-adjusted the valves. Two of
> them were loose. Took care of that quickly. Did a compression test.
> Compression was good. Pulled injector wires one at a time, but it doesn't
> seem like any one cylinder is missing constantly. Checked the timing, and
it
> looks good, although the mark bounces around a lot. The problem is that it
> has a rough idle and it hesitates on acceleration and at constant speeds.
> Gas pedal to the floor at 65 mph. The cap and rotor don't look so great,
so
> I'll be replacing those tomorrow, but I don't expect it to make a whole
lot
> better, because there seems to be a serious lack of power. Hopefully
someone
> has a suggestion. My van has been sitting for 6 weeks, and I can't wait to
> take it out on the road again.
>
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