I agree with Dennis. you need to do some tests. My first thought is to
monitor fuel pressure.
Ken

On Mon, December 12, 2011 11:49 pm, Dennis Haynes wrote:
> It always pains me to see folks troubleshoot by changing parts until it
> works. Engine performance issues always come down to an engine problem,
> (rings, valves, valve train), fuel or air delivery, or ignition. While it
> may start and run initially don’t rule out an engine problem. Your 20K
> BB rebuild means little. Things happen.
> Perform a compression and leak down test. Any discrepancy make sure the
> valves are opening when they should.  My van recently beat me up with a no
> fire cylinder #1. Compression even checked good. After a while I noticed
> the intake runner for that cylinder was warm while the other three were
> cooled by the air going through them. Removed the rocker cover and found
> that somehow the push rod came out from the rocker. Reseated and all was
> good.
>
> John L recently had the number 1 intake valve stem wear down enough for
> the keeper to fail and valve fell into the engine. He also changed a bunch
> of parts. When I met him in Florida I almost instantly electrical parts
> were not going to fix it. You have to know the engine is good.
>
> For ignition make sure all the plugs are sparking. It is fairly common for
> the ignition wires to fail at the spark plug end. Those connectors can
> either short out or open. Either no or weak spark to the plug. With the
> engine idling disconnect the injectors one at a time. You will find the
> cylinder that is not contributing.
>
> Then check for fuel-air delivery including vacuum leaks.
>
> Use the O2 sensor as a diagnostic too. A voltmeter can be used with a good
> sensor to check that the mixture is correct and that the controls are
> working.
>
> Clogged exhausts and catalytic converters make distinct sounds.
>
> Dennis
>
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
> Joel Cort
> Sent: Monday, December 12, 2011 4:07 PM
> To: vanagon@GERRY.VANAGON.COM
> 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
>
>