EFI issues, now it is hydrolocking

[westernair]

OK so most know I installed an EFI kit on my pinz. Truck has been running great once I figured out a few minor issues.
Now last Friday things started happening that caused problems.
On the way up to the gold panning location we went to, I found the truck would sputter and pop when starting it up cold. It would take about 5-7 minutes before she would run fine. This happened all weekend as we drove around.
Then on the 150 mile drive home 4 times it started doing the same thing on the freeway and then would die. while still coasting down the freeway I would turn the key off and back on and she would snap back and run great again until the next time.
Figuring it was probably a loose wire or something, when I got home I went through and checked all the connections. After checking them I started the truck up again and found it sputtering and popping again. I then pulled a multimeter out and started checking 12 and 24 volt wires. While doing this, I left the ignition on but had not hit the starter button. Then all of a sudden I started smelling gas and looked under the truck to find gas leaking out of the header pipe to heater box connection.
quickly I turned the power off and after a bit it stopped dripping. Next I checked wire connections to the injectors and then thought I would try turning the engine over. I quickly turned on the power and tried the starter button to find it would not spin at all, it also started leaking gas again. At this point I just stopped.
So I assume I need to pull the plugs, suck the gas out of one or all of the cylinders and then???
Any ideas on what I should do?

[edzz]

1. Pull the spark plugs, turn engine over manually (by hand) to expel most of the gas. than suck it out or use air to blow it out / dry the cylinders.
2. Check your oil for gas contamination you may need to change it.

3. I'd be finding a fuel injection expert. Jim ya listening?

Than if it were me id change back to carbs (being that I don't know crap about fuel infection) if I had to guess I'd be guessing you have a problem with the computer, on freeway turn key off, turn key back on I'm guessing would reset the computer and purge the flaw temporary.

OK now that its obvious I don't know anything about fuel injection. however I stand by points 1, 2, and 3.

Hopefully some one will chime in that knows fuel injection.

[audiocontr]

Remove your plugs and see if they all smell of gas or just one. Could be a bad injector, which would be an easy fix. Otherwise you're into controller territory.

[edzz]

Remove your plugs and see if they all smell of gas or just one. Could be a bad injector, which would be an easy fix. Otherwise you're into controller territory.

could/would one bad injector cause it to die on the freeway?

like I said I don't know FI systems.

[berger]

Like Ed, I know nothing of FI, but could it be the mechanical fuel pump? Air lock caused by hole in fuel line?

[westernair]

I have a friend more familiar with aftermarket EFI systems used on air cooled VWs. He indicated he would stop by the house next week and look at it. This weekend I need to replace the trans shaft seal and bronze bushing on my Haflinger. With Levenworth fast approaching I need it in tip top shape.
I will however check all the plugs and oil before he comes over.

[westernair]

I am running a new german fuel pump capable of 200 psi. My regulator has the fuel pressure to the rail set at 40 psi which is what the EFI kit recommends.

[Jim LaGuardia]

Most likely a bad or sticking injector, that or the fuel reg has failed. Also check crank sensor lead for chaffing, it takes an electrical signal to open the injector

[westernair]

Turns out it was grounding issues. A bad ground, and a grounding loop in all the wiring.
Cleaned the gas out of the cylinders, changed the oil and away she goes.
Happy happy happy

[edzz]

Happy Happy Joy Joy

Glad this turned out to be an "easy" fix, good trouble shooting.

[berger]

Good stuff!