endless Hiccoughs and temporary cutting out.

[Jim H]

Hi,
I'm at my wits end and need help, it's my only car and I've been on foot for 6 weeks now! the depression is getting all to real.

I've had my 92 GT2 EX Webber for about 18 months... The first year it was fine, but the day before the MoT (Christmas time) it started hestitating under harder acceleration, so I started going through the usual (I've had 3 before).

Since January I have replaced the vacum lines, dizzy, the filler neck, tank, all the feul lines, feul pump, swirl pot, carb flange, rebuilt the carb, and retimed it... and the feckin thing still won't run right..... it seems different every time I touch it (although that could me, my brain chasing it's tail).

I'm fairly sure the carb needs better fettling, but there is no point in doing that properly until the feul supply is consistent.
... if I boot it it Hiccough or grumbles (back off and reboot and it's usually ok).... going up a steep hill it kept trying to cut out..... it seems to be an intermitant feul starvation issue, not enough to cut out completely but only just - not sure how I made it up the hill to be honest. Nearly everything is new so I don't understand how this can be...... One thing I cannot seem to do for love nor money is get all the air out of the filter, which makes me suspect airlocks....how do I get rid of them? (I tried a vacuum pump... feul came through but the air stayed put).

I did try the 3 way split with the welding tip instead of the swirl pot, but that didn't seem to make any difference at all.... and it should run fine with the swirlpot anyway.

I'm tempted to try a one way valve in the inlet feul line, just as it comes out of the tank, to stop the line draining back into the tank, is this a good idea?

.... I honestly don't know what to do next and I'm close to tears of frustration, so any suggesting are welcome, please.

[RussGLAuto]

Sounds like you have done all the right things so far.

Do you still have the vapour trap fitted or was that removed with the Webber conversion? I have had a Webber fitted to my FR in the past, now back to the original Pierburg, on both setups there is / was always air in the fuel filter. Not sure that is your problem.

In any case, sounds like one of the jets in the Carb may be blocked. Have you had them cleaned out at all and / or the carb serviced? If not, try that as a starter for ten.

[Jim H]

thanks.... I tried it with and without a new swirpot, didn'T make much if a diffetence.
I think I may have found a large part of the problem... the secondary main emulsion tube is a bit compresed/bent, the jet is 130 instead of 127 and my primary main air corrector was a 140 instead of 145.
bits on the way, so I hope that sorts it.

[C 20 CCO]

A new inlet manifold gasket did it for me, i like you went to the edge of sanity. Even with a vacuum gauge to test how strong the suction from the pump was. In the end the gasket was my saviour. Fiddly but do-able as a diy.

[WreckTangle]

I gave up on the Weber (fitted by a previous owner) and reverted to a Pierburg which I stripped down, cleaned, rebuilt and adjusted according to the service manual. This eliminated similar problems for me plus restored the benefit of an automatic choke.

Had I persevered with the Weber I would have checked the jetting like you have. I think it is quite common for them to be supplied wrong unless bought properly set-up from a reputable source. I would also have checked the float level and needle valve.

Has yours got the throttle body heater fitted? This part is transferred across from the Pierburg. Does it work and is it actually in contact with the throttle body? Mine wasn’t.

[RussGLAuto]

With you on that one WT! The Webber is (allegedly) set up for a 2E2 Carb, mine is a 2B5 hence the jets were incorrect. It was running so rich it was only delivering 16 MPG and an asthmatic 55 hsprs, not the 85 the FR should have.
VW Heritage UK & Webber boast a plug in and play set up for their carbs and infers that they are better than the original Pierburgs:

"To fit 1.6 engines with automatic transmission. This kit replaces the 2E2 Pierburg original caburettor which are known to have running problems."

Shame on VW Heritage for suggesting it is.

Now the original PB Carb is fitted refurbished with clean fuel it's running sweet as. Rust contaminated fuel manifested as difficulty starting, ran for 50 yards then lost all power and stalled.

[C 20 CCO]

Did you ever get to the bottom of your problem??

[james butler]

its well worth double checking the obvious and go back to basics
the main issue with diagnosing this issue is youve done so much work to the car its hard to pin down the issue
however it does sound like a fueling issue
start by a clean down of jets and check the fuel system
a lot of people accidentally bend the fuel floats when dissasembling the weber so may be worth the check.
start one thing at a time

[C 20 CCO]

I didn’t touch my jets in the carb, but like you changed most of the other components. Like I say my problem was with the inlet manifold gasket; impossible to diagnose. Good luck, and if you resolve this issue, let us know for reference

[RussGLAuto]

I hope all have been satisfied?

[C 20 CCO]

Is the car still sat idle, or is the issue fixed.

[whiteshark]

How old are your HT Leads. Start it at night time, open the bonnet and check for any arcing when you rev the car. Feel your pain, I only have fuel injection now. Do not miss the carb days, all that troubleshooting and stripping everything from the fuel neck to the carb.