76 Westy Running Rough Need Ideas!!!!!

[MrGolf]

My 2.0l fi 76 Westy sometimes misses and bucks a little while under load. ( up a hill or grade) Not all the time. Sometimes no problems. Seems like a misfire or only running on 3 cylinders. On the flat it runs great. Put new plugs, wires, cap points and rotor in 2001. I have only put 4,743 miles on it from then to now. Since 4/24/08 I have driven it only 327 miles. It sits in a garage with a wood floor. Never been left outside. Not even overnight!!!! Am going to pull the plugs just to check them. probably still perfect. Could I have a bad injector? If so how do I trace it down? I removed the points tonight. Installed a petronix. Started it up but it is idling a little lower than it should. Alternator light starts to come on till i give it a little gas. Will drive it this weekend. How do I increase the idle a little. The old points were pitted and I have petronix in my 69 and 72 beetles and love it. Any ideas wouild be appreciated. Thanks

[ajdenette]

How old is the Gas in the Gas tank if you drive it that little? old gas does not burn well even with stabilvand could cause it to run rough. to increase the idol you should have some kind of tacometer attached and there should be an idol adjustment screw on the side of the throttle body that will let you increase the idol but it soulds like it time for a round of adjustments with the new petronix.

[MrGolf]

I do need to run it and get more fresh gas back it. I do put stabil in it every year like clockwork when I store it. I do have a tach on it. Not sure what the idol should be set at. Have the books for the beetles but not the bus. Going to pull the plugs today just to check them. Rotor and cap still look new and plug wires are fine. Will look on the throtle body for idle screw. I think I set it up a little a few years ago. No adjustment to petronix. Just gapped the module at .030 like my other ones. I would like to drop the engine and check it all out. Looks like a big job to do. Not like a beetle engine when you can have it out in a 1/2 hr or less.

[luke78]

Check your temp sensor 2. It may not be within resistance spec, or it may be coming unscrewed.

[MrGolf]

Just got bus back from the garage. $967 later. Clutch etc., all new fuel line, timing set along with valves. New clutch cable and other stuff done when engine was out. Starts great and idles great. Runs super till the first time I hit a grade again. Just like last time. Under load it seems like 3 cyl and loses power. Anyone have any ideas why. All new plugs wires cap and rotor and fresh gas. New Petronix and coil too. Like I said, great on the flat but any grade or hill is when it craps itself.

[Piledriver]

Check your temp sensor 2. It may not be within resistance spec, or it may be coming unscrewed.

+1
Also, does it have a WOT switch?

The next thing to check would be the AFM, need a DVM, make sure it doesn't have any dead spots.

Most equipment of any description dislikes sitting around.

Old gas is also your enemy, more now than in the past.

[Jadewombat]

Take it back to the shop and tell them they need to fix it right.

[wildthings]

Dump some FI cleaner into the gas tank and see what happens.

[MrGolf]

What do you mean does it have a WOT? Whats AFM & DVM you said I should check. Not ringing a bell.

[Piledriver]

What do you mean does it have a WOT? Whats AFM & DVM you said I should check. Not ringing a bell.

WOT= Wide Open Throttle switch. On throttle body, usually underneath. You may not have one.
AFM=airflow meter, attached to the air cleaner, gray metal bit. A spring loaded flap moves inside to measure the air going into the engine.
DVM--- Digital volt meter.
..Bit of test equipment that should be in your toolbox,
...so you can spend 5 minutes to personally check out the WOT switch and the AFM, and the temp sensors etc and not have to pay some idiot $1K to not fix your vehicle properly. (although it looks like he did other things)

You may have gooped up injector, or a bad connection, or any number of small issues the mechanic would be delighted to charge you $100/hour to investigate, until you run out of money.

The common ground array under the plenum (where it's a PITA to get to) is a prime location for bad grounds.
These critical grounds should all be reterminated with sealed crimp loops and put under a nut and washer.

Injectors can be cleaned and flow tested. You can do the latter.
Buy a set of Bosch green CIS injector orings for the injector seals, works FAR better than the originals. (Thank you, Ray Greenwood)

LJet is a pretty simple system and you can FULLY check it out in under an hour with a DVM and a fuel pressure gauge.

Also-- replace ALL the fuel lines in the vehicle if you haven't already.
Sounds like a big job... It really isn't.

[MrGolf]

Would a weak fuel pump possibly be the problem? What I mean by that is I use to be able to hear it while it was running and when I originally turned the key on. Now I hear nothing. It starts fine and idles ok but I wounder when I have the demand for more fuel it could weak and not putting out the pressure that it should? Not sure how much pressure it puts out. Just a thought. Allgrounds are good and all electrical connections were cleaned when engine was put back in.

Thanks

[fusername]

fuel pressure guage worth every penny. if it sounds expensive, look at what a shop would charge to test it for you, and remember how unlikely it is they will test it right. Bosche has some VERY easy to read and follow testing instructions for this fuel injection, it is very worth downloading and having next to yo uwhile you poke and prod things.

[MrGolf]

How do I remove the fuel injectors on my bus. (76 Westy) Looks like I remove fuel line from both ends of fuel rail. Then unplug the electric connection on top of the injector. How do the injectors come out. If I grab it will it simpley pull out or is there more I should know? Don't have the maintenance manual. Want to pull them and clean them as I still have a miss under load. Can not think of much more it could be as wires ,cap, rotor are almost new. Timing set and valves adjusted along with brand new plugs. Thought I might have a weak fuel pump. Installed new Bosch last week. Still have the miss. Idles great. Or would I be better off just putting new ones in? They are oem. Guy at the beetle shop told me that injectors in these buses rarely ever go bad. Oh ya filled up with fresh gas yeterday and it also has a new fuel filter. Would like to get this sorted out before snow flies here in PA..If I pull them do I need new O ring seals. If so who sells them? Also who sells the best replacement injectors for this bus.

Vin is:2362134689

Thanks

[fusername]

one 10mm nut right above each injector, carefull you don't loose the washer under it. Then you just pull the injector away from the intake and it will come out. there are two rubber seals, one large one under the metal clamp, a smaller one around the snout. soemtiems the smaller one stays in the intake. the little ones should be replaced to ensure a good seal.

[Piledriver]

The "little ones" are best replaced with Big Fat orings...
...the Bosch CIS green viton orings ~$3 ea. Worth every cent.