Joel,
 
I'd still put a little suspicion on the muffler clog idea unless you've  
actually run it w/o the muffler.  On that run down to the gas station,  maybe 
you could do it with the muffler shifted over to the right, about 1/2"  from 
the Cat.  It will be VERY loud, but could either eliminate the muffler  as 
potential source or pinpoint it.
 
Jim Davis
 
 
In a message dated 12/12/2011 1:07:09 P.M. Pacific Standard Time,  
JOEL_CORT@YAHOO.COM writes:

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]

------------------------------------

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.

Yahoo! Groups  Links

<*> To visit your group on the web, go to:
http://groups.yahoo.com/group/Syncro/

<*> Your email  settings:
Individual Email | Traditional

<*> To  change settings online go to:
http://groups.yahoo.com/group/Syncro/join
(Yahoo! ID  required)

<*> To change settings via email:
Syncro-digest@yahoogroups.com 
Syncro-fullfeatured@yahoogroups.com

<*> To unsubscribe from this  group, send an email to:
Syncro-unsubscribe@yahoogroups.com

<*> Your use of Yahoo! Groups  is subject to:
http://docs.yahoo.com/info/terms/