2.1 DJ overfuelling

[slamdunk]

Right, here goes. My 2.1 was in covered storage over the winter. Checked fluids, coolant was low, so topped up and she started first turn of the key. Took her on a spin without any issues and popped £20 of fuel in her. Hot started without issue and parked back up. Thought I would get a mobile mechanic out to give the van a once over and do a pressure test on the coolant system as I couldn't see any evidence of a coolant leak.

He has a look at the system and couldn't find a leak either. While he was there I asked him to look at my timing as I haven't done a thing to that side of the van since I got it and I haven't seen north of 20mpg.

During the course of his prodding and poking, the van cut out. It was a bugger to restart and had deffo flooded. I had used up the time allocated, so booked another slot the following Wednesday for a full service to get it running spot on and it had a been a year since the last oil change. One thing he did do was suck on the vac advance unit to verify its operation and it changed the engine tone proving it worked. Everything else was a prod and a poke.

He turned up and focused on getting the timing right after the previous weeks messing. He reckoned it was spot on, but every 5 minutes it would 'cut out' and take 5 minutes before it would restart. I read on here that that sounded like the temp2 sensor issue. He checked all the inputs to the ECU and reported that they were within the range specified in Haynes.

I went to the van at the weekend and it started fine; didn't smell as rich as before the service after a cold start. The idle speed was higher, but not ridiculous. I stopped the engine after a few minutes and tried to restart it with no avail - flooded. I started it a few minutes later and it had deffo flooded - one cylinder caught, then the next, etc.

Took it on a drive and after 1/4 mile the van started sputtering, I dipped the clutch and the only way to keep the van running was to have my foot to the floor. It was barely ticking over and really sputtering and hesitating. It cleared after 30-40 seconds and was a bit lumpy as I drove back to the barn. I restarted the engine fine then. But the farm entrance is onto the A14 (like a motorway only without a hard shoulder) and frankly the idea of it dieing on me there isn't very appealing.

Anyway as it seems to flood or nearly flood, I think I can rule out the temp2 sensor and am left a bit clueless. I have replaced the air filter, disty cap, disty arm, plugs. I have a coil on order. But the spark did look good.

help!!

Slam

[slamdunk]

PS. I am replacing the main earth tomorrow night - I have some monster braid with crimps welded on.

Also as a consequence of this I cannot get to the spray shop where the owner had cleared a space in his diary to fit the camper in, so have let him down big time too.

Slam

[AdrianC]

Anyway as it seems to flood or nearly flood, I think I can rule out the temp2 sensor

Not sure you can. It's the Temp2 that "pulls the choke out". That's the biggest influence on the richness of the mixture.

Other than that, it's the AFM, the injectors and the fuel pressure regulator that I'd start by looking at.

[Aidan]

I'd be checking the TCi unit, but first I'd check the vacuum hoses to the disi and the fuel regulator, if they are leaking then timing will go out and fuel pressure will be max'd out and will over fuel and I'd check that the spigot the vac hose plug onto in the plenum chamber is clear by reaming it with a small screwdriver or drill bit

[slamdunk]

Anyway as it seems to flood or nearly flood, I think I can rule out the temp2 sensor

Not sure you can. It's the Temp2 that "pulls the choke out". That's the biggest influence on the richness of the mixture.

Other than that, it's the AFM, the injectors and the fuel pressure regulator that I'd start by looking at.

New Temp2 sensor on order. Will fit on Saturday....

Slam

[slamdunk]

I'd be checking the TCi unit, but first I'd check the vacuum hoses to the disi and the fuel regulator, if they are leaking then timing will go out and fuel pressure will be max'd out and will over fuel and I'd check that the spigot the vac hose plug onto in the plenum chamber is clear by reaming it with a small screwdriver or drill bit

The vacuum hoses to the disti were ok - I was able to suck on that and it changed engine speed/ note. I haven't checked the piping to the fuel regulator. I will give that a check on Saturday. The van is several miles from home and I don't get home till after dark.

Slam

[slamdunk]

Today, I have replaced the temp II sender (nice and easy to get to isn't it??), replaced the engine earth with some serious braid, checked the AFM (fine, nothing odd), cleaned the idle control valave with carb cleaner, replaced about 200 litres of coolant due to the old gasket staying in the thermostat housing and me not being able to get it out! checked the idle microswitch on the throttle body and it still does the balck smoke, dying, dying gone, flooded. Restart two minutes later as if nothing had happened.

I have a coil from a MkII Golf that has the same connection arrangements. Can I damage the ignition amp with it? Is it worth a shot?

Any ideas on how to check the fuel pressure regulator - I don't want to splash out £100 if it isn't that, same goes for the ignition amplifier.

If there was someone near Cambridge with a 2.1 that was willing to temporarily swap bits until the problem was found, that person would be rewarded with copious amounts of beer/ beer tokens!

Slam

[slamdunk]

Will this fit? Thought that trying a second hand one first to see if it cures the problem might be a better option....

http://www.ebay.co.uk/itm/VW-AUDI-IGNIT ... 4ac20373e5

Slam

[slamdunk]

New coil fitted - no difference. Fine for 5 minutes then splutters, revs drop, black smoke, cough and die.
TCI unit next - the one in the van is a Telefunken unit (part # 191 905 351 B) with a date stamp of 89, so probably original.

Slam

[AdrianC]

New coil fitted - no difference. Fine for 5 minutes then splutters, revs drop, black smoke, cough and die.

Sounds like it's starting to run very rich as it warms up. You've replaced the TempII, but have you checked the wiring between it and the ECU? Make sure you're getting the right resistances through.

What happens if, once it starts to splutter & black smoke, you disconnect the TempII?

[KINGPRAWN]

My DJ overfuled to the point of a hydraulic lock!!!! Turned out to be the ECU had had a terminal moment of madness ... CJ at syncrospares had one on the shelf and with the help of a big wrench a bucket and a few hours it was sweet as again....... But ohh maaan the smoke as we left the garage for the first 1/4 mile was AMAZING!!!!!

[slamdunk]

but have you checked the wiring between it and the ECU? Make sure you're getting the right resistances through.

What happens if, once it starts to splutter & black smoke, you disconnect the TempII?

The mechanic told me that he had buzzed out the harness at the ECU, but he failed to spot that the "terminal oil leak" was the low pressure sender which had cracked over the winter..... I will buzz it out once my new TCI unit arrives...

I had assumed that if the TCI unit was disconnected when the engine was running it would run horrendously rich anyway as the input to the ECU had gone to infinite resistance. Again something I will try once Mr Postie delivers my TCI unit.

I wish I had room on the drive for the van - driving several miles to it is a PITA.

Please keep the suggestions coming.

Thanks,

Slam

[slamdunk]

My DJ overfuled to the point of a hydraulic lock!!!! Turned out to be the ECU had had a terminal moment of madness ... CJ at syncrospares had one on the shelf and with the help of a big wrench a bucket and a few hours it was sweet as again....... But ohh maaan the smoke as we left the garage for the first 1/4 mile was AMAZING!!!!!

I bet that was cheap!!

Slam

[AdrianC]

but have you checked the wiring between it and the ECU? Make sure you're getting the right resistances through.

The mechanic told me that he had buzzed out the harness at the ECU, but he failed to spot that the "terminal oil leak" was the low pressure sender which had cracked over the winter..... I will buzz it out once my new TCI unit arrives...

"Buzzing it out" will just show that it's connected, not what resistances the ECU's actually seeing, versus what the sender itself is giving.

If the ECU doesn't see the TempII at all, it'll go into a default mid-point mode, I think. The problems start when there's a wrong, but viable, resistance being read.

[slamdunk]

but have you checked the wiring between it and the ECU? Make sure you're getting the right resistances through.

The mechanic told me that he had buzzed out the harness at the ECU, but he failed to spot that the "terminal oil leak" was the low pressure sender which had cracked over the winter..... I will buzz it out once my new TCI unit arrives...

"Buzzing it out" will just show that it's connected, not what resistances the ECU's actually seeing, versus what the sender itself is giving.

If the ECU doesn't see the TempII at all, it'll go into a default mid-point mode, I think. The problems start when there's a wrong, but viable, resistance being read.

Sorry - I did mean checked the resistance, not just checked continuity.

Slam