81 Scirocco smog check fixes update

Installed new plug wires and distributor cap... tested vacuum
retard/advance... cleaned crud-encrusted injectors and tested for good spray
pattern... installed new injector o-rings and buckets... checked cold start
valve for leakage... removed and thoroughly cleaned throttle body...
installed new o-ring on idle screw... sealed vacuum leak in plastic intake
tube... replaced cracked-and-sealed-with-electrical-tape 'connector hose'
between plastic intake tube and throttle body... installed new O2 sensor.

Engine now seems to run OK but idle's a problem. With idle screw turned
almost all the way in I can barely get down below 1K rpm by adjusting the CO
screw lean. But then, when I do the dwell meter CO test per
http://vintagewatercooleds.com/tech/Techtips/Timbotechnotes/emissions/emissi
ons.htm
the dwell is over 85 - supposedly way too lean. But manifold vacuum is about
18" hg, higher than the maximum of 16" recommended in the Clymer manual. The
least dwell I get by enriching CO is about 52 (and it doesn't fluxuate
much), but at that point the idle is above 1500 and manifold vacuum is above
20".

I just removed the old Emico CAT. Can still see through screens but exhaust
pipe upstream and down is caked with carbon!

Tomorrow I check timing again...could all the vacuum leaks being sealed have
altered it? Will also install new Bosal CAT (jeez, what sloppy welds!).

Concerned about engine noise. Quiet enough at idle but when I open the
throttle there's a hell of a rattling noise. I'm wondering if the timing
belt tensioner is going bad. It's possible it has over 150K miles on it.

nf


.

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