[T3] gas mileage, voltage, etc.

[Jim Adney]

On 26 Jun 2017 at 21:53, Daniel Nohejl wrote:

> I wanted to add that I pulled the spark plugs a few hours ago and
> found that 1 and 4 were fouled and 2 and 3 were white as heck 

This is all dissapointing. It sounds like your efforts to tighten the 
connectors didn't work out as hoped. There are a couple possible 
causes for this. It's possible that you didn't squeeze the connectors 
hard enough. They are small and stiff, so it takes a bit of pressure 
to have an effect. Unfortunately, there's a fine line between enough 
pressure and too much pressure. That's why you have to check each 
female pin on a male pin before you put them back into the connector 
body.

The other possibility is that these connectors have been manipulated 
too many times and they have passed their fatigue limit. Once past 
that limit, they will crack along the side and no further tightening 
will ever be possible. At that point, the only option is to replace 
the pin, which requires expensive tooling and hard to find pins.

If you can get here, I have the tooling and the pins, but you have to 
get here on all 4 cylinders.

The wires in your photos look fine. It's pretty typical to see the 
insulation pulled out of the rear crimp. I don't see any broken 
strands and the important front crimps look good.

You should also check the tightness of each of the several ground 
connections at the center of the case. Two of those carry the 4 
injector currents. It's important to note that when Bosch made their 
harnesses, they made them such that neither crimp connector carried 
two currents at the same time. So, for example the ground wires for 1 
& 2 (or 1 & 3) could be crimped together, but not 1 & 4, since 1 & 4 
fire together.

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Jim Adney, jadney at vwtype3.org
Madison, Wisconsin, USA
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