Dear Diary - Wrapping up a fix
From: Paul Bennett (pbennettmacnet.com)
Date: Wed, 23 Aug 2006 11:00:21 -0700 (PDT)
Think I've found the problems.

Bought more washers for the leaking banjo fitting and learned:
1) The washer OD is critical as the lower washer fits into a recess.  
2) The banjo bolt was bottoming out - adding a thicker washer on top cured the 
leak.

Warm start conclusions:
1) Terminal to the ThermoTime Valve were connected BACKWARDS.  Each wire does a 
job and if you reverse them, the cold injector squirts fuel when starting a hot 
engine, flooding it, requireing wide open throttle to encourage clearing 
excessive fuel and starting.
2) First test of learning fuel pressure was important to rule out the check 
valve and accumulator.  This also allows testing the bellows in the warm fuel 
regulator.  Differential vacuum pressure between top and bottom chambers in the 
regulator cause fuel pressure of 30 psi cold and 50 psi hot.  Also allows 
gunning engine to insure pressure change at increased and decreased vacuum 
which leans mixture on deceleration and enrichens it on acceleration (WOT).

Cold idle:
1) Place a 3" length of 1/4" vacuum hose in the rubber 'L' hose restricting 
idle to 1200 rpm.  
2) However, solution I am going with is rerouting vacuum hose bypassing the 
ElectroValve, providing full time vacuum to the AAV cold start bellows.

Refreshed several cotton braided hoses:
1) Bought 5mm grey braided vacuum hose from VW dealer - 2M for $20.
2) Haven't found any 9mm so am using 1/4" rubber for now.
3) Haven't found any 22MM but temporarily replacing my motly braided one with 
gates green stripe 7/8" ($4/ft)  


Just double checked the warm start - engine run until fans came on - went out 
10 minutes later - engine starts quickly at first touch of the starter and no 
pedal.  Good job well done...still think there is an element of the engine 
wanting some quality time with me tho.

fin






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