1978 FI Bug Vert

[MikeH]

Purchased on 6-14-09. Thanks to Dave who posted the samba ad in the classifieds. I saw this at 10:00 a.m. on Tuesday. It had been posted the evening before. Guy said he had 40 calls on it.

When I talked with him he didn't seem to have any serious buyers on the hook. I suspect the engine not running scared away all the fake Bug people who just want a cute car.

I told him I would be there by 5 pm if he would hold the car. Sometimes you just have to take a chance.

The car is in fairly rough condition but is solid enough for a straightforward restoration if I wanted to take it that far. And the price was very right. He wanted it gone so for the price I figured there was only upside. It will make a real nice summer ride if I just get it running.

I'll post some pics later.

[MikeH]

Ok first thing ups is to get the engine running.

Checked the oil, it was about an inch over the full mark on the dipstick. Yikes. I hope it was not running that way. Drained some out till it was back to normal full.

I pulled the coil wire and tried to get a spark. No spark. That's a real good sign the problem is electrical. I ran a wire directly from the battery to the coil and managed to get a thin weak spark but the engine wouldn't start.

I didn't have time to check if I'm getting spark at the plugs. Mosquitos were having me for dinner. I'll replace the coil first and then have another go at it.

[MikeH]

[dave]

Is it still fuel injected?

[MikeH]

It is fuel injected which adds a whole nuther dimension since I know zip about FI.

Yanked the coil from my Ghia and got spark to the plugs. Still doesn't start. So much for it being simple. That was a real downer since I was convinced it would be the coil. Now I'm forced to learn the FI.

Next up is determining if I'm getting fuel to the cylinders.

[gokart]

Carburators are cheap. But, hopefully it is something easy with the injection like a fuel filter.

Pull off the air filter and pour like a table sp oon of gas down the intake. If it fires up then dies, you must have a fuel problem. If it doesn't fire it could be other things (or you flooded it).

Did you know you can't type sp oon? It posts as "sthingy". The auto censor won't let me type "fork n sp oon". What does it have against silverware?

[dave]

I do not know a whole lot about fuel injection, but there are a few things you can do before you rip it out and carb it,and if you want I have 78 vert with fuel inject so I might be able to help you.

Odds are good that it may be just a dirty connection(even though I have never been that lucky).

[MikeH]

Well Fuel Injection is definitely not as easy to trouble shoot. Engines starts then dies after 3 seconds. At that point it refuses to start.

Let it set for 5 mintues and it will start for 3 seconds and die again.

Acts like the fuel is being shut off. I have a thread going on Samba and have tried a long list of things but haven't found the culprit yet.

www.thesamba.com/vw/forum/viewtopic.php?t=367760

[dave]

This is what I did and found out I had a Bad pump:

Disconnect the wire that goes to your points,then open up your air filter there is a flap in the throat towards the engine,Now i used a paint stick to open it up(with the engine switch on,not cranking, you should hear the click of the relay.
Now go to the front passenger side where the fuel pump is,it should be running,if not check your wires at the pump with a volt meter just to make sure you have 12 volts. If it is not running and power is going to it you may either have a clogged fuel filter or a bad pump(or just dirty connections).

It is a start anyways. Oh and if you replace the fuel filter get the one for fuel injection.

[MikeH]

Well I think I'm now an expert in FI or close to it.

Tested compression 138 all around.
Adjusted valves.
New points installed
New plugs installed
New plug wires
New coil
Dwell set
Static timed to TDC

Tested every connection to a sensor
Tested the double relay
Tested voltage, resistance and continuity where appropriate
Tested the fuel pump during start and with the Air Flow Meter propped open.
Removed injectors and tested spray patterns, looks good,

Tested fuel pressure : 38psi

Still doesn't start, but it sure wants to.

[MikeH]

After checking and rechecking suddenly determined I had stopped getting a spark from the coil. Noticed the points had twisted. Straightened them out but still no spark.

As I turn the engine with a static timing light hooked up it never turns off. No idea how that happened but something went bad.

Very strange.

[dave]

That is strange,Never heard of points twisting,time to try another set of points.(and condenser)

[MikeH]

Points were definitely melted and overheated. Cheap points. But it was my fault. Left a hardline from the battery connected to the coil overnight. Oops. New points arrived and back to where I started. Engine sputters but won't start.

Last night I discovered the ECU has a pin missing. Now that seems important. That particular pin doesn't seem critical to me but who knows, the ECU is basically a black box. I'm now on the hunt for a replacement ECU. I can buy these new but they ain't cheap.

Located a potential used one on Samba.

In the meantime I pulled the injectors and put on all new seals and fuel line segments. Also, cleaned all the electrical connections.

Now I'm back to waiting till I get my hands on an ECU.

[MikeH]

Bought a used ECU off Samba today. Figure I can resell it if I don't need it.

While I was under the car with a light, testing the fuel pump, my son was turning the key on and off for me says... "Dad, I can see your light."

Turns out the rust holes up front are a wee bit larger than I first thought. Very repairable though. In the front firewall. Not my main concern at the moment. I

I'll throw up some pictures soon.

[MikeH]