Hi Paul,

CIS injection can be a PITA to deal with when it isn't running right,
and a lot of parts are hard to find or very expensive.

Here are three possible solutions not previously mentioned listed from
cheapest to dearest.

You can get a weber carb kit for that engine for around $500. You would
also need a new low-pressure fuel pump to supply the carb, but that's
only $50 or so.

Another option would be to swap the cylinder head to that from a later
model 2L Golf or Jetta and then convert to Digifant fuel injection as
was used in the 1986-91 vans. In practical terms you'd probably need a
donor car to do this swap since you would need the wiring harness,
computer, intak, etc.

Third option: Consider replacing the engine with something later from a
golf/jetta. It'd be a simple bolt-up mechanically, though the
electronics and fuel system would take some rework. It's certainly got
to be a LOT cheaper than $12K though, and if you start with the right
donor car you get a fresh(er) engine as well.

If the shop won't consider these options you are dealing with the wrong
people for the care of that vehicle.

Happy Trails,

Greg Potts
1973/74/79 Westfakia "Bob the Tomato"
1987 Wolfsburg Weekender Hardtop
www.busesofthecorn.com
www.pottsfamily.ca

Paul Chubbuck wrote:
> For over a year, my Vanagon engine has been surging badly, especially when
> the accelerator is fully depressed, as it frequently is at highway speeds.
> The rate of surging at highway speeds is approximately 2 cycles per second.
> The surging can be minimized by backing off at bit on the accelerator, but
> since the engine is underpowered for the vehicle, it is not acceptable to
> use anything less than maximum acceleration.  At street speeds it is much
> less noticeable but even then there is often unsteady acceleration.  It
> makes driving unpleasant and rough.  Sometimes the problem will suddenly
> cease and there will be smooth running for anywhere from a few seconds to
> several miles, but otherwise, it is there most of the time.
>
> It is a 1982, originally diesel, but converted before I owned it to what I'm
> told is an 86-92 Rabbit/Fox engine.  The computer has Bosch number 0 280 800
> 104 (105) on it.  It is fuel injection.
>
> I have been told by two different seemingly competent shops that the problem
> lies in a part numbered Bosch 0 438 101 005, which I believe is called a
> fuel flow meter or a fuel injection pump.  Not sure of that...I'm not a
> mechanic, as must be obvious.
>
> The first shop to work on it had it back at least 5 times before they gave
> up.  They tried cleaning and adjusting that component to no avail.  They
> couldn't get a new part and tried replacing with a used part and said the
> other used parts performed worse than my own.  They also replaced the O2
> sensor.
>
> The 2nd shop said replacement of that part would cost me $2000 because the
> part is not made any more.  They offered to do an engine conversion to a
> Suburu for $12,000!
>
> Can you tell from the symptoms if this part is really the culprit?  Is there
> any way to replace this part at a reasonable price?
>
> Thanks very much in advance.
>
> Paul Chubbuck in Fort Collins
>