Club 80-90 Forums

Two things; I'm looking for mechanic in the Manchester area who can diagnose and repair engine running issues, would also really appreciate any advice on the running issues that I can get from anyone on here.  

The van's been looked at by several people over the last few years but never resolved fully. It's had hunting and cutting out issues for sometime, including struggling to start again when warmed up. The clutch went on me trying to get it to the last mechanic too. Recently had the Injectors & rail changed, new air intake sleeves, new starter, new plugs, new earth strap and new clutch. Currently, it starts and runs fine from cold, then either cuts out and won't start or idles fine then when switched off won't start (like it's flooded or fuel starved). Supposedly the plugs have been checked and aren't wet. Also, the clutch has been changed but supposedly needs the slave cylinder bled or changed. 

I've been online searching and seems it could be multiple issues or just one very simple thing, like an earth wire. There are couple of things I understand might still be the issue AFM being aged and worn, the ECU not functioning properly, possibly temp sensor. There also might a possibility of rust from the fuel tank restricting fuel supply. These are all expensive and some seemingly hard to get hold of parts. So would like to try and find the right person to help get the van running properly again. 

The guy who's looked at it, has done his best but thinks I need a specialist to look at it. Does anyone know someone that understands the quirks of these vans and can methodically go through the process of testing the wiring and ECU etc? Any helpful advice would be much appeciated, thank you. 

Full engine diagnostic procedures for the DH are in the Bentley manual so you should have a copy of that, either digital or paper: diagnostic time can be pretty unlimited timewise and thus expensive, so you are better off doing the work yourself and getting up close and familiar with it. Have you owned the van the last 16 years since you joined 80-90 or is this van new to you ?

It's difficult to guide you remotely unless you know a bit and understand the systems in play; Sam16v had issues with a new to him 2.1 but he's a mechanic so it wasn't hard to point in the right direction so he has been able to sort his running issues - but from experience a lot of mechanics who aren't T3 experienced will end up bodging stuff to get it off the ramp and then wipe their hands of it, and undoing previous bodgery is worse than fixing stock system that hasn't been messed with.

DH is pretty rare in the UK so spares for the unique bits of them aren't easy to find as you'll be aware. More of them in the states so the Samba may be a better resource than here or UK facebook groups. I don't know anyone in the Manchester area working on these vans anymore since MAC closed. Nearest is John at VW Camperhaus but last time I spoke to him his wait list was pretty long.

Aiden, Thanks for the prompt reply. Yes, I've had this van since 2008. Although, sadly I haven't managed developed my mechanical know how or confidence in that time, apart from the very basic troubleshooting. I get 'getting up and personal' is the way forward which I'm prepared do with my Bentley manual but I fear I'll take it part and won't get it back together. Really, needs some know how on it. 

It was suggested to get 'new' AFM but from searches, it's bit like rocking horse sheet. I think I can get this from Vanagain, over the water. I'm prepared to do as it definately could do with an upgrade, just would help to know I'm not throwing money away first, as I'm not convinced it will solve the problem. There seems to be UK company that refurbishes them, but not so sure about that being the right way to go either. AFM might be a bit of red herring atm. 

The engine block is original and I've tried keeping as much as possible original as possible, apart from a LPG conversion from Gassure in 2009. I'm looking to get rid of this now too. I'm reluctant to kop for a scooby do motor but it's an option, kind of!

I am actually happy to take the van anywhere in the Uk if it means it's getting the TLC it needs. It's done me well all these years and I'm sure still has much life in there, somewhere. 

Dream and Drive in Holland do an optical operation AFM in exchange for the original one - I am running one in my van but I haven't done enough mileage to absolutely say it is perfect, but my DJ seems happy with it at the moment, but I have a spare standard AFM that is known to be fine in the van which I carry should the new one go breasticles up. Personally I don't trust any company in the UK to refurbish any of our ignition system - happy to be proved wrong, but generally they have lost the skills from that era, and are only really advertising a generic service with little to back it up and we know of many peeps who've coughed up hundreds for refurbished ecus and the like that weren't perfect and then the warranty claim is just a blame game, so you need someone who knows their onions and really there aren't that many options. That's the main reason for the scooby engine change, not because the wbx isn't an option but maintaining it has become so problematic and the skill base so eroded with Bosch/VW no longer providing warranted refurbished parts like they did in the 90's and early 2000s - back in 2007 I could go to my local parts factor who was a Bosch agent and just buy a disi, AFM and Idle control unit, on exchange, warranted factory refurbished unit, and my local Bosch agent could buy genuine parts for the starters and alternators from Bosch as well for not silly money and my local auto electrical could easily refurbish these parts and give them a proper second life.
The peeps who could do a great job with WBX electrics can't justify the time to do it, economically it makes no sense to their business, customers wouldn't be prepared to pay the real cost, why spend £100+ to individually refurbish a starter motor properly when you can buy a generic chinese one that will do the job, ish for £60, many of the 'refurbished' units are ones from scrap yards just de-rusted and painted black in Eastern Europe and given a Hella or similar sticker which means diddly squat

In the check list of thing replaced I cannot see TCI or DIS mentioned, or cleaning of injector earths or the main harness earths for that matter.
Go cheap, early!

Why does everyone assume that the AFM is at fault? A worn track and resultant poor signal usually leads to hesitant acceleration, not a failure to start.
Temp sender failure would make it run rich (usually)
ECU failure tends to do things like flood the engine with fuel or no fuel at all.

I would swap the TCI for a new one, thoroughly clean the earth terminal cluster below the coil and on the LH head (unbolt and pickle the ring terminals, not just a wire brushing) and bypass the DIS.
Also check the state of the idle module behind the RH real lamp, gently unplug it and make sure that its not full of water or has green terminals.

And check/swap the coil in case it is breaking down when hot. In fact check all the ignition components for cracks or anything suspect.

And do a suck test on the vacuum system just to make sure that the dissy capsule diaphragm hasn't failed, often forgotten and it leads to lean running at idle.