try it with oxygen sensor disconnected.

I don't see where you have checked the actual fuel pressure ( unlikely it's
off though )
I'd try another distributor ..
though when those mess up it's more won't-start or cutting out .

I doubt the idle control unit is causing the problem ..
no harm in trying another one.
I don't see that the throttle switch making contact at idle and WOT has been
checked or fixed.

I would use mid-grade but not premium, seriously.
and ..fwiw..
I just found a ton of water in a Vanagon's tank..
and a near clogged fuel fitler ....
and the new tank is only 5 months old ...
( that was a smaller 84 style fuel filter pre-pump, since removed and new
large fuel filter installed )

I have not seen a syncro fuel tank clog up ..I have seen them not feed fuel
when pretty low though.
Some  times I run vans on a completely different fuel tank rigged up in the
back seat ..
though I don't think you're there quite yet.

I don't see anything about Temp Sensor II .
I would check extensively for vaccum leaks ..
though I don't think that's it ...
I have found up to 10 tiny vaccum leaks on the entire intake system from
throttle body to intake ports. ..on one engine.

re
Air intake boot – swap - sucks plenty of air just fine

it's not that they don't suck air right ....they always do that ..
it's that a cracked one can suck air in a big crack ....what's called 'false
air' .
Sometimes there is a crack but it only opens up under engine torque.

I had a turbo volvo of mine doing exactly the same thing ..
drove me nuts ...acted like clogged cat ..wasn't.
finally found it ..
after a certain amount of boost .......boost pressure would cause this one
oil-rotted main hose to open on the side..
which cut air flow through the AFM ( air mass meter really , on that 88
car ) ..
the the AFM would see less air flow ..
thus ECU would cut back on fuel .

( here's a similar one ..new TDI conversion same thing ..won't go over 50
mph. Guy worked on it for a couple of months ..finally he had someone watch
the engine while he drove..
an intake hose was collapsing under suction , restricting air flow. )

check your air boot and associated hoses very carefully ..
and I can't help saying ..
check/clean/test/inspect more ...as opposed to just trying parts.

heck....pull the injectors out and check their spray patterns ....still
attached to the fuel hoses on the engine ..
for example.  Probably not it either ..
just an example of testing-inspecting-cleaning-checking as opposed to just
trying parts.

btw....I seldom *ever* hear about any techicians considering the fuel
itself.
I've seen water in fuel a lot , especially at this time of year. 'Usually'
it's not a real problem ..
but the fuel itself should always be sampled ..and considered.

Scott
www.turbovans.com
  ----- Original Message -----
  From: Joel Cort
  To: Syncro List ; Vanagon_List
  Cc: Emp_VW_Camping_Club@yahoogroups.com
  Sent: Monday, December 12, 2011 1:07 PM
  Subject: [Syncro] Help needed with engine running poorly

  Sorry for cross posting but there are experts on both lists.

  It really sucks when you are the mechanic and you don’t know what to
do.... so with my tail between my legs I turn to these forums for any
assistance.

  I have an 89 Syncro Westy with the stock Boston Bob 2.1 Liter gasoline
engine with about 20K miles on the clock.

  Symptoms are that it start fine, idles fine, revs up fine without a load
and with a load it dies out at about 3000 RPM.  So about when you engage 3rd
gear to get going ..... Nothing and it loses power from there.   Luckily I
am in my driveway and not somewhere on the road in Wyoming.

  IT was suggested to me, by several mechanics on site at Westies at
Watkins, who know more than me, to check the air intake, the fuel pressure
or I may have a plugged muffler/catalytic converter.

  OK All good areas to focus on so the first thing I did was change the fuel
filter.  No changes and I went from there changing and swapping one
component at a time and going for a test drive.  Here is every component
that I have changed, tested, adjusted, syncro-nized and still I get no
satisfaction.

  1.      Fuel filter - new
  2.      Fuel pump - swap
  3.      Fuel pressure regulator – swap
  4.      Ground wire checked and cleaned
  5.      Temp II sensor - new
  5.     Air Flow Meter – swap  PS (I have the Vanagon Syndrome capacitor
soldered into the AFM plug)
  6.     Air intake boot – swap - sucks plenty of air just fine
  7.     Throttle body cleaning and new seal
  8.     New vacuum rubber hoses
  9.     Air filter - new
  10.   Spark plugs - new
  11.   Spark plug wires - new
  12.   Catalytic Converter – see through baffles relatively new
  13.   Muffler – relatively new – no mouse nests
  14.   Oxygen Sensor - relatively new
  15.   ECU - swap
  16.   Distributor - swap
  17.   Coil – swap with another green coil
  18.   Timing – set per Bentley
  19.   Fuel lines replaced last year
  20.   good exhaust manifolds, no leaks

  It's a real bummer; man!
  The only other thing that I can think of is to swap out the idle computer
module behind the taillight since the sensors and ECU connect in on this and
it may send  goofy signals to the ECU at various times.
  Also I have not messed with the charcoal canister and that section of the
fuel venting system. Should I?

  I will stumble down to the gas station and refill the tank with good high
grade gasoline just in case there is some bad fuel as well.

  Are there any other things that I have missed?  Any help or suggestions or
areas to re evaluate will be considered.

  Thanks,
  Joel Cort
  Rochester NY

  jcort@rochester.rr.com
  joel_cort@yahoo.com

  89 Syncro Westy (VanGo)
  87 Syncro Transporter (Stella Blue)
  73 Westy Campmobile (Agent Orange)

  Western New York LiMBO Representative www.limbobus.org
  Founding member of the Empire State VW Camping Club
www.empirevwcamping.org
  Westies@Watkins XI is planned for September 21-22-23, 2012
www.westies-at-watkins.org

  [Non-text portions of this message have been removed]

  __._,_.___
  Reply to sender | Reply to group | Reply via web post | Start a New Topic
  Messages in this topic (1)
  Recent Activity: a.. New Members 1
  Visit Your Group
  Please note that the default "Reply" function will route your reply to the
entire group. If you have a private message for a member you'll need to
specifically address your message to them.
  If you would like to modify your subscription settings (including
unsubscribing), visit:
  http://groups.yahoo.com/group/Syncro
  Rude or offensive language is not allowed on the Syncro list. Please try
your best to resolve differences privately and keep them off the list.

  MARKETPLACE
  Stay on top of your group activity without leaving the page you're on -
Get the Yahoo! Toolbar now.

    Switch to: Text-Only, Daily Digest • Unsubscribe • Terms of Use.

  __,_._,___
----- Original Message -----
From: "Joel Cort" <joel_cort@YAHOO.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Monday, December 12, 2011 1:07 PM
Subject: Help needed with engine running poorly

Sorry for cross posting but there are experts on both lists.

It really sucks when you are the mechanic and you don’t know what to do....
so with my tail between my legs I turn to these forums for any assistance.

I have an 89 Syncro Westy with the stock Boston Bob 2.1 Liter gasoline
engine with about 20K miles on the clock.

Symptoms are that it start fine, idles fine, revs up fine without a load and
with a load it dies out at about 3000 RPM. So about when you engage 3rd gear
to get going ..... Nothing and it loses power from there. Luckily I am in my
driveway and not somewhere on the road in Wyoming.

IT was suggested to me, by several mechanics on site at Westies at Watkins,
who know more than me, to check the air intake, the fuel pressure or I may
have a plugged muffler/catalytic converter.

OK All good areas to focus on so the first thing I did was change the fuel
filter. No changes and I went from there changing and swapping one component
at a time and going for a test drive. Here is every component that I have
changed, tested, adjusted, syncro-nized and still I get no satisfaction.

1. Fuel filter - new
2. Fuel pump - swap
3. Fuel pressure regulator – swap
4. Ground wire checked and cleaned
5. Temp II sensor - new
5. Air Flow Meter – swap PS (I have the Vanagon Syndrome capacitor soldered
into the AFM plug)
6. Air intake boot – swap - sucks plenty of air just fine
7. Throttle body cleaning and new seal
8. New vacuum rubber hoses
9. Air filter - new
10. Spark plugs - new
11. Spark plug wires - new
12. Catalytic Converter – see through baffles relatively new
13. Muffler – relatively new – no mouse nests
14. Oxygen Sensor - relatively new
15. ECU - swap
16. Distributor - swap
17. Coil – swap with another green coil
18. Timing – set per Bentley
19. Fuel lines replaced last year
20. good exhaust manifolds, no leaks

It's a real bummer; man!
The only other thing that I can think of is to swap out the idle computer
module behind the taillight since the sensors and ECU connect in on this and
it may send goofy signals to the ECU at various times.
Also I have not messed with the charcoal canister and that section of the
fuel venting system. Should I?

I will stumble down to the gas station and refill the tank with good high
grade gasoline just in case there is some bad fuel as well.

Are there any other things that I have missed? Any help or suggestions or
areas to re evaluate will be considered.

Thanks,
Joel Cort
Rochester NY

jcort@rochester.rr.com
joel_cort@yahoo.com

89 Syncro Westy (VanGo)
87 Syncro Transporter (Stella Blue)
73 Westy Campmobile (Agent Orange)

Western New York LiMBO Representative www.limbobus.org
Founding member of the Empire State VW Camping Club www.empirevwcamping.org
Westies@Watkins XI is planned for September 21-22-23, 2012
www.westies-at-watkins.org