repeated condenser failure

[MarshallGTi]

that was my 1st attempt at repair, i gave the original condenser a squeeze with pliers to see if that would let the car start. it worked, so i knew where the problem was. but even that squished condenser only lasted about 50km

[MarshallGTi]

just to add, if/when the car drives it only goes out on a short weekend drive. so these condensers are all failing in less than about 75km worth of driving. this is why i think theres something more serious causing the failures.

[MarshallGTi]

update : fooked again...
new condenser fitted, resistor removed, timing done 100% properly, CO's set, etc and running really well. drove to roadworthy place and back and total about 47km, misfiring again and struggling to start etc, and feels like condenser again. if i can nurse/tow it to the parents place where all my tools are i'll swap in the last new condenser i have and i'm pretty sure it'll be fine again.

now, why in the name of all things brown and sticky does my car eat thru condensers? is there possibly a certain wire thats maybe shorted or crossed that could cause this? is it anything to do with the coil and/or resistor? i'm sick of throwing money and weekends away at a car i cant even drive.

[Tony Z]

when last did you replace the rest of the ignition circuit? Points, plugs, wires, rotor and cap?
Maybe you need to get to an auto electrician? If you do, please find out what the problem is/was so we can also learn from it.

What are your coil primary and secondary readings?

Another thing.... What happens if you leave the car after the coil has failed for 20min? Does it restart and drive for 50km again?
Why am I asking??? Your fuel filter is in a CRAP location near the hottest part of the engine. You need to move it out of the engine bay to a spot next to the gearbox. I suspect you might be having fuel boiling issues which could possibly be the problem you are looking for (and not a condenser).

[MarshallGTi]

hey Tony

when i bought the car in August, it had just had a motor overhaul, and the bougi's/distributor/points/coil are all new.
i have also put new plugs and new condensers very recently. i have 3 coils lying around and the problem happens no matter which coil i use.

as for the coil readings, they were all within the specs mentioned earlier in the thread, but i will check again and post. the coil doesnt get excessively hot either.

moving the fuel filter is on the list (as is a fire extinguisher) but i dont think the problem is related to that, as i let the car stand all night and tried again in the morning and the same issue pops up straight away. to add, on the way to get roadworthy done, i climbed some pretty steep hills and i reckon that if it was boiling fuel it would have shown up there already.

like i said, i'll put in the last of the new condensers i bought and if it works after that then i really am at a dead end.

[IMPI]

Hi What kind of fuel are you using?
LRP also gives the same symptoms i have gone over to using regular unleaded and my car is happier for it
Armand

[MarshallGTi]

Only been using 93 unleaded from engen.

[retrovan]

may I mention the most basic question, that we all failed to ask from the start, IS your motor well earthed.

Do you have a earth strap from your body to your gearbox, over the gearbox mount.

This will blow your caps, is the coil well earthed, as a bad earth will through back into your cap.

Herman

[MarshallGTi]

coil earth is fine, i made sure of that. main earth strap looks fine but i'll pull it off on the weekend and get out the wire brush just to be sure.

[MarshallGTi]

right, so i managed 48km this past weekend on the new condenser, and not one single hiccup yet
checked the earthing, and all looked great. even got a very good reading of 1.1ohm from the dizzy case to the taillinght screws...
decided to start checking wiring to the coil after u guys saying it could be too much or too little voltage. i found one wire, all of 3 or 4 inches long, that i couldnt get a consistent/decent reading on. jumped anywhere between 40 ohm and 75 ohm. got rid of that, neatened up the wiring a bit and off we went. i'm very chuffed now. even my seatcover (who has understandably been quite anti-beetle of late) was thoroughly impressed and asked if we could take it for another spin yesterday

for the record, the one coil had a reading of 2.1 ohm and i used this with the resistor, the other (currently fitted) reads 4 ohm and is now wired without the resistor.
i suspect that dodge wire was causing times of far too little voltage to the coil, and at times spiking too much voltage. anyways, i'll use it to get groceries this week and find the scenic route to the shops and see if all goes well.

thanks for all the help and input guys, i owe u beers

[calooker]

Been using Bosch components since the Elchlin crap started giving me crap as well, not a single problem since, even my 1400 nissan bakkie is using a modded beetle one now, geting 15000 km service intervals no problem, where the Elchlin crap was having to be changed several times, that includes the points as well. Bosch items are pricey but well worth every cent.

[retrovan]

Good to hear its running fine now.

Now put the dented cap with the ones you know that work into the Beetle tool box, you will need them some time, and OH!! do not change a cap if its still working, it will keep working longer then the NEW one.

Herman

[flatfourfan]

now.......as I said months ago.........move that fuel filter.

[MarshallGTi]

yes boss

[flatfourfan]

Dude, just don't want to see a bug go up in flames..