Well, I've had a nice three day weekend of truck work. Let's list what happened:

Friday AM: Attempt to change out cap, rotor and wires to clean up ignition system. As I go to remove the cap, one of the two bolts snaps. Wash hands, get in the Jetta and go to work.

Friday PM: Get home from work and decide that I'm going to need to remove the distributor to get the bolt out. Decided it would be easier if the manifold weren't in the way. Begin tearing down engine.

Saturday: Get up and start working cleaning the gasket surfaces. Replace plenum gasket as original is sticking out beyond the steel plate like lunchmeat on a sandwich. Spray intake manifold with Mopar CCC liberally and watch the oil go away. Spray into ports on the heads. Took Shopvac and sucked up all loose debris in the lifter valley and intake ports. Remove injectors from rail for inspection, spray them and the bungs with MCCC and reassemble. Install 180 degree T-stat and gasket. Find intake gaskets that I thought I'd forgotten. They were sandwiched in between the two pieces of cardboard that the rubber gaskets for the manifold come on. Finding that out after going to four different places on a Saturday evening to find nobody stock the gasket was a bit annoying. Remove distributor after finding out that unlike a SB Chevy the distributor is separate from the gear. Drill out old bolt, clean up distributor, drop in and install rotor and new cap. Reinstall manifold and torque everything to spec. Had my woman turn the key to pressurize the fuel system to check for leaks. Injector 2 gasket pisses fuel all over the place. Go to Murray's and get injector o-rings.

Sunday: Replace both injector o-rings on Cylinder 2 and recheck. No leaks. Finish assembly of engine. Install plugs wires in right order, double check all work. Start truck and runs like a bag of s*it. Doesn't idle properly, sounds like it has a vacuum leak since it's surging badly. Detonates over 2K RPM. Find out that plug wire are in the right order, but all are off by one post. Reinstall wires, start truck. Still has issues, but sounds much better. Remove cap and TDC engine, adjust distributor position to properly aim at Cylinder #1.

Drove the truck Sunday evening and all day yesterday. Getting better than 15 MPG but won't know until I get through a full tank.

On another note, the electric fans were worth doing. I used a set of LS1 Camaro fans from a 98 T/A that I bought for $110 plus a electric fan controller (180 degree switch). It take some fabrication, but definitely a worthwhile mod. I'd do a writeup on it, but it was really not something most people would be up for. The truck is running well under 200 (probably around 170 or less) cruising on the highway, but I see no problems with CEL's or anything else.

I've attached the pics of the fans to this thread. This first pic if of the water pump pulley. It's not like what is in the book. The tool for it costs $40-$80. I built it for less than $10. The fans do not cover the entire core, but the rule of thumb is if 80% or great surface area is covered by the fans it will cool properly. These fans cover just a bit over 80%.

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Pics attached here.

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your fuel sync is probably off, take it to a shop that has the right scan tool and have them re-set it.

nice fan install, do a writeup anyway since you never know who might want to do it after you...

 

I've got an Autotap on order, should have it soon.

I'll do the writeup of the electric fan install in the next couple of days. I didn't take a whole lot of pics, but I am happy with the results.