TheSamba.com :: View topic - Getting the 1986 "Westy" back into shape!

Sat Oct 20, 2012 9:16 am

This thread is for the 86 Weekender, for the 90 Tintop follow this link........

https://www.thesamba.com/vw/forum/viewtopic.php?t=746871

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NOTE: Sadly there were time periods that I couldn't upload photos to thesamba or they were not VW specific. I used Photobucket which has recently prevented 3rd party hosting of photos. (July 2017)
I'll try to fill in the missing images using another host site as time allows..... so sorry.

Well, I guess it's time to make a build thread for my recently acquired 1986 Vanagon Westfalia "Weekender".
There are a few rogue threads asking specific questions about this car but parts are ordered, time to get this Puppy on the road!

The facts:
Model Year: 1986
Partial build date: 5/86
Final build date: 7/86
WV2XB0252GH112***

W - Germany
V - Volkswagen
2 - Multi Purpose Vehicle MPV
X - Kombi
B - 4 cylinder gasoline, water cooled
0 - passive restraint, seat belts
25 - Vanagon
2 - Manufacturer Check Digit
G - Model Year (1986)
H - Hannover (Assembly Plant)
112xxx. Sequencial Production Number

Color:
Sales Code: S8S8
Paint Code: LH1V
Paint Name: Savannah Beige Metallic
Pop Top color: Desert Beige (no code)
Interior: Beige Corduroy Seat Covers and door panel inserts
Brown Dash with Brown accents for plastic levers and knobs
Beige Vinyl Door Covers
Pebbled Beige Ceiling and similar on Floor.
White/Beige storage cabinet in LR window.
Beige/Tan Pop Top tent fabric.
Mileage: 116,171
Factory Full Wheel Covers on Steel Wheels
Transmission: Automatic 3 Speed
Engine: 2.1 Water Boxer MV015458
Power Steering
Factory Air Conditioning
Standard Instruments, just clock, no tach
Added VDO cockpit series gauges

Coming Home....

Home being "inspected" by the family......

Dave

Sun Oct 21, 2012 4:26 pm

Calculating torque....
"
EverettB Wed Nov 07, 2012 10:03 pm
Here's a post I made a while back in another thread about the gland nut

EverettB wrote: Here's what I do:
Get my breaker bar and big socket.
You need 250 ft. lbs. of force so that is 250 lbs. at 1 foot out from the socket.
1 foot = 12 inches.

Say you weigh 175.
So take 250/175 = 1.43
12 inches x 1.43 = 17.1 inches.
Mark a line on the bar at 17.1 inches.
Get someone to hold the engine, I usually have my wife put her foot on the opposite cylinder head with the engine on the ground.
Stand on the bar with all your body weight at the line you just made. I usually have to brace myself on my car or put a hand on a nearby tool chest.
When the bar stops moving downward from your weight, you just applied 250 lbs.

Don't jump on the bar or you will over tighten it.
It takes less force than you think.

I use this method to do the rear axle nuts too."

Depressing!
I made a complete "to do" and a "to purchase" list today! I'm sure that it will be proven to fall far short of the real finished list!

Job #1:
The rear deck lid shocks are shot. The PO was nice enough to include the cut off broom stick used to prop the lid open.
I wanted to have the gas opening assist and to not have to hold it up as I put in the stick. I also don't like the idea of the stick getting knocked out and the lid crashing closed on my back!

So, two new cylinders, cleaned up the rusty mounting balls as well as the short shaft, lubed them with grease and clicked in the new cylinders.

Heaven! :)

Before....with stick

After....no stick!

Dave

Sun Oct 21, 2012 4:40 pm

Job #2

Oil change:

This Van has sat for ten (10) years I'm told. The battery is dead, dead, DEAD!

Before doing any diagnosis work, I wanted the old oil OUT! I'm sure the engine is almost completely dry and I don't want it's first pump of lubication in a decade to be old moisture entrained lubricant.

I pulled the rusty drain plug out and BLACK Texas gold poured out! Thick and dirty! :(

I grabbed the rusty oil filter (a Fram :( ) and attempted to turn......not even a budge. I got out my Giant Channel Locks and with some effort it finally broke loose but took almost a full rotation before I could hand spin I off!

Installed a new oil filter, cleaned up the drain plug and put it in.

Filled it up with just shy of 5 qts of 10w-30.

I went to the fuel pump and pulled off a wire, I don't want it pumping the probable sludge in the fuel tank to the injectors!

Now for a new Battery......

Dave

Sun Oct 21, 2012 5:20 pm

Job #3

Touch up paint color test.

Today was sunny and unseasonably warm, a perfect day to touch up some scratches on the Van.

I had picked up a pint of Savannah Beige Metallic from my Auto Paint store.....

Not wanting a big project I simply used the edge of a tightly folded up fragment of a Bounty Paper towel as an applicator "brush".

I'm happy to report that my guys mixed it quite well. Yes, it's looks like you expect a dab of paint to look, it has been touched up but is no longer a white line. I've got some empty touch up bottles with the brush in the cap, if I can find them I'll fill them up to make things easier.

Dave

Mon Oct 22, 2012 3:32 pm

Job #4

New battery:

Picked up a battery today, pulled the old one out. The old one was much bigger, much taller so that the PO had bent up the cover mounting lip at the rear of the battery box. The length filled the box completely. Something else to repair....the battery box!

Cleaned up the terminals and hooked them up, the Van sprang to life!
The Radio was not tuned on a station so I got static at full volume, the wipers were on, key buzzing, lights came on, interior lights came on and the Turn signal was flashing.

Lots of action! Shut things down one by one and tried the key for starter....not even a click. Just silence. Tried Park & Neutral to no avail. I guess that it is Time to start diagnosing things, I'll start with hot jumping the starter itself to verify that it works.

Dave

Mon Oct 22, 2012 3:39 pm

Check the wiring to the neutral safety switch located in the shifter housing. The switch itself tends to shift and misalign. Try all positions of the shift handle to see if you get anything.

Mon Oct 22, 2012 4:35 pm

Nice Van.

If you would like to eliminate the use of the hatch stick I have a solution for you. Take off one of the worn out hatch shocks and go to your local hardware store. Buy a piece of ABS or PVC tubing that will slip over the large part of the shock. Re-install it on the van and the tubing will hold the hatch up. I only used it on one side.

Have fun.

Mon Oct 22, 2012 4:36 pm

I've brought a few busses back from the dead over the years. 10w30 is no good in a boxer, except to flush. It's perfect for that. Run that oil and filter for 500 miles. Then change.
Same with the Trans. Change the oil with cheap stuff and change again in 500 miles.
Drain the fuel tank. It's not even worth trying to get that fuel to work.
Then pull a hose where they go into the injector cigar tubes one side at a time and pump fuel out there with the fuel pump.
Once you've got both with fresh fuel, hook back up.
Plan to change your spark plugs in about 50 miles.
Change all your brake fluid and coolant as well.
I do all these things before even trying to get an engine to run.

Once it runs the temptation to not update the cooling, brakes,and Trans will be too great.

Mon Oct 22, 2012 5:14 pm

Phishman068 wrote: I've brought a few busses back from the dead over the years. 10w30 is no good in a boxer, except to flush. It's perfect for that. Run that oil and filter for 500 miles. Then change.......

Flushing I am doing. I don't plan on driving it until I diagnose the entire engine and determine the need for mechanical repair. The PO said he parked it 10 years ago due to coolant loss, he indicated head/s.

I wish to do a compression test, coolant system pressure test and a leak down test. If these results are bad I may get it started to help scrape 10 years of cylinder build up off and test again.

I plan on pulling the engine and trans to do a complete seal replacement.
While the assembly is out I plan to replace the engine oil cooler, transmission oil cooler, all heater hoses, all radiator hoses, probably heater control valves as well. I am seriously considering installing Go Westy's plastic coolant pipe repair kit.

http://www.gowesty.com/library_article.php?id=113

Ok, back to oil. Because of my great respect for Tram and good advice I've gotten from him over the years, I'll use his recommended oil, Castrol Syntec 5w50. http://www.thesamba.com/vw/forum/viewtopic.php?t=116835

Thanks for the other advice, I'll check out the neutral start switch.

I've got a tentative first long trip scheduled for Easter 2013 to my Sister in Laws in Indiana. (Her house is so broken, dirty and "icky" I desire to bring my own bedroom! :) )

First I've got to finish the Super Beetle! The Westy sits outside the garage door awaiting permission for entry! :). (The Karmann Ghia body has been removed from its bay for the winter making room for the Westy)

Dave

Mon Oct 22, 2012 6:31 pm

I would certainly get the engine working, and well before pulling it. That's just me though.
Fix leaks once it runs well.

Tue Oct 23, 2012 7:35 am

Nice Rig, is this your first westy?

Do you have enough head room in your garage for a westy? Doesnt look like its going to pass through. Then it needs to be raised off the ground another 12 inches to work underneath. Its a curse for most us having to work outside : )

Tue Oct 23, 2012 9:41 am

Boostd wrote: Nice Rig, is this your first westy?

Do you have enough head room in your garage for a westy? Doesnt look like its going to pass through. Then it needs to be raised off the ground another 12 inches to work underneath. Its a curse for most us having to work outside : )

This is MY first Westy. I did have a 71 Kombi years ago. My parents had a number or Campers. A 1968, 1973, 1978 and ended their camping run with a 1973 Toyota camper.

Height?

Ah! I had the presence of mind to measure that before I brought it home :lol: I've got 2+ inches at the skylight.
Well..........
Honestly, kudos to seller who asked me about height. His garage is miniature WWII era!

As far as height to jack it up? About 10", if I remove the garage door opener, almost two feet!

Yeah, that opener is probably gonna go!

Dave

Tue Oct 23, 2012 10:00 am

We have a very similar model, maybe made a month after yours (number 114,xxx).

We really, really like it. Been gradually fixing it over the last couple years, all the while doing lots of trips and excursions. It keeps getting better despite some of the mechanical headaches!

The body on yours looks to be in pretty good shape all things considered.

Nice find, enjoy!

Tue Oct 23, 2012 10:05 am

teej wrote: We have a very similar model, maybe made a month after yours (number 114,xxx).

We really, really like it. Been gradually fixing it over the last couple years, all the while doing lots of trips and excursions. It keeps getting better despite some of the mechanical headaches!

The body on yours looks to be in pretty good shape all things considered.

Nice find, enjoy!

Thanks, I'm happy with the purchase overall. Considering that it is a Native North Eastern US unit the rust is surprisingly minor. The Right Rear wheel area has a bit of rust, even perforated through into the wheel well. Outside of that? Nothing of note. I even looked under the footwell pads at the front doors.
When I pull the interior I'm sure that "discovery" may become painful!

I attribute the low level of rust to it only having 116,000 miles in 26 years. It was their vacation unit since 1990 so most likely saw little of the NE winters fury!

Dave

Tue Oct 23, 2012 10:13 am

uncommonvw wrote: Nice Van.

If you would like to eliminate the use of the hatch stick I have a solution for you. Take off one of the worn out hatch shocks and go to your local hardware store. Buy a piece of ABS or PVC tubing that will slip over the large part of the shock. Re-install it on the van and the tubing will hold the hatch up. I only used it on one side.

Have fun.

New struts are so cheap, might as well do it right and not worry about another part laying around in the trunk.

http://www.van-cafe.com/home/van/page_470_165/hatch_strut_-_right_or_left_2_required.html

22 bucks each. no brainer.

Mon Dec 31, 2012 9:33 am

This is a great thread. I scored an '86 Westy a couple years ago, but am tackling the mechanics finally now. Pretty stoked.

http://www.thesamba.com/vw/forum/viewtopic.php?t=539428

Thu Mar 21, 2013 4:57 pm

So......... Spring's coming!....... Technically came yesterday but it snowed last night! :cry:

I've remained true to myself to NOT touch the Westy until the Super Vert is DONE!

But....... Spring's coming!

The Super just needs a no nonsense intense Weekend of Window fiddling and interior install. I've driven it already. :). No mirrors, one seat, no brake lights...... Heat worked good though! It's amazing what solid heater channels do for a car!

The Westy has a cracked and leaking Skylight. I've had a bucket under it all winter. I've obtained a replacement from theskylightguy along with new gasket.

I need to pull the top, clean it well, kill the interior mold, repaint it and install a new skylight and canvas.

I know this violates my no Westy pledge but it's important! Like a leaking roof on a house, first thing to fix.

I've started a thread about BusDepots canvas and as a result of feedback on the product I have ordered one....
http://www.thesamba.com/vw/forum/viewtopic.php?t=548231

I've researched paint for the top and have settled on using Interlux Brightside.......

http://www.thesamba.com/vw/forum/viewtopic.php?t=462517

I've even begun delving into a new interior......

http://www.thesamba.com/vw/forum/viewtopic.php?t=546298
http://www.thesamba.com/vw/forum/viewtopic.php?t=536086

But, the fact remains, the Westy is going to usurp the Bug any day now! The top must happen soon!

I see a concerning pattern developing, I'm focusing on the interior and visual items rather than mechanical items. I advise others to focus on mechanicals first, eye candy later......and most often do this myself.

I think my wife being involved has changed the emphasis and repair order.
She won't go into and spend time in an "icky" situation happily.

But........

She will tolerate a breakdown if She's got a good clean place to sit or lie!
Heck we started our long relationship with breakdowns! For instance...... Rebuilding the carb on her 66 Ghia on our wedding night! Broken down in front of a Crematorium on a long lonely dark highway!

I'm thinking of making the interior glisten, pull the dash and clean out any mouse crap, seal off their entry points and make this her little rolling castle.

I'm thinking short trips this Summer / Fall. Close enough to call my kids to bring the truck and towbar! :oops:

I'll go through the Brakes, change the oils, replace the FUEL lines (yeh, I can read and comprehend repetitive comments made here), replace belts and some hoses, replace coolant, make it run and barring any catastrophic discoveries, carefully run for the Summer and Fall....... Knock on wood.

I've a great compact travel tool box! Pack that and my Bentley. Renew my AAA membership with the top tier towing plan.......really........how bad can things go wrong?

Tell me I'm not crazy!

Dave

Thu Mar 21, 2013 9:30 pm

Holy smokes! How in the heck do you get seat wear like that?! Did the PO wear jeans made from sandpaper?

Thu Mar 21, 2013 9:41 pm

RainierSyncro wrote: Holy smokes! How in the heck do you get seat wear like that?! Did the PO wear jeans made from sandpaper?

it's a VW - and VW chose the infamous shredded cord seat fabric for a few years

maybe the same guy who designed the air-cooled-engine-in-a-water-shroud and the far-famed blue foil instrument panel connector

Thu Mar 21, 2013 10:03 pm

djkeev wrote:
I see a concerning pattern developing, I'm focusing on the interior and visual items rather than mechanical items. I advise others to focus on mechanicals first, eye candy later......and most often do this myself.

I think my wife being involved has changed the emphasis and repair order.
She won't go into and spend time in an "icky" situation happily.

But........

She will tolerate a breakdown if She's got a good clean place to sit or lie!
Heck we started our long relationship with breakdowns! For instance...... Rebuilding the carb on her 66 Ghia on our wedding night! Broken down in front of a Crematorium on a long lonely dark highway!

I'm thinking of making the interior glisten, pull the dash and clean out any mouse crap, seal off their entry points and make this her little rolling castle.

Perhaps it's the girl in me, I'd say you don't really have a choice, but to do the interior with it destroyed like that. It's no longer protecting the foam, so unless you *also* want to replace the foam when you do the fabric portion, I wouldn't really call it eye candy.

And, a mouse in the dash is going to start a fire, so also kind of a necessity too.

Make it *go* this summer and pull the engine next winter and rebuild it if you like, but you don't have time now anyway, so may as well enjoy for the summer!

Wonder if anyone has ever gone to VW and complained about that corduroy fabric and actually gotten anywhere. I know it's 27yo, but mine's 26 and other than a wear spot here and there, still looks great!

Enjoy!

tam