kamzcab86 Samba Moderator
Joined: July 26, 2008 Posts: 7893 Location: Arizona
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Posted: Mon Aug 27, 2012 1:41 pm Post subject: Vanagon Essentials ~ The FAQ Guide |
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Last update: March 22, 2018
Vanagon FAQ Index
Clicking the links below in this index post will take you to the desired section, but will open in a new tab/window. You may also simply scroll down to the desired post/section. Pro tip: Use your browser's "find" command (ex. Ctrl + F) to do a keyword search for subjects you're looking for.
This FAQ Guide is sectioned and enumerated to match the Bentley Service Manual for Vanagons.
General Info
- Type/Model information
- Buyer's Guide
- Paint colors/codes
- VIN
- Engine code/number
- Transmission code/number
- Lifting van with jack/hoist
- Towing: General towing info; hitches; trailers; roadside assistance
- Insurance
- Thefts & theft-proofing
- Repair shops, parts/product info, technical info & online manuals, tools, apps
- Van Fires: Why they start, how to prevent them, & how to put them out
- Vehicle Care/Maintenance
- Name this part!
- Owners' realm
Engine, Cooling, Fuel, Exhaust, Ignition, Electrical
- General info
- Cylinder heads & valve drive
- Lubrication system
- Cooling system
- Fuel system
- Exhaust/emissions system
- Electrical: battery, starter, alternator/charging, ground locations, solar set-ups
- Ignition system
Engine Conversions/Swaps/Rebuilds
- Who does conversions & rebuilds?
- General info
- Upgraded WBX
- Subaru
- Volkswagen I-4, 1.8T, VR6
- Zetec/Bostig
- Tiico
- Audi
- Porsche
- Diesel
- Air-cooled to water-cooled
Clutch & Transmission
- Clutch, controls
- Torque converter
- Manual transmission
- Automatic transmission
- Differential
- Transmission swaps/alternatives
Suspension, Steering, Brakes, & Tires
- Front wheel suspension
- Rear wheel suspension
- Wheels, tires, alignment
- Brakes
- Steering
Body (Interior, Exterior) & HVAC
- General body information: dimensions, paint, modifications, etc.
- Hoods/lids (aka rear hatch)
- Doors
- Sunroof
- Tarpaulin
- Bumpers
- Glass, window regulators
- Body accessories (side moldings, mirrors, etc.)
- Seat belts
- Interior trim
- Seats
- Seat upholstery, heating element
- Heater/ventilation
- Air conditioner
- Insulation, sound-deadening, odors, & rodent problems
Camper
- Roof: pop-top/high-top
- Interior panels
- Storage & cabinets
- Tables
- Water tank(s)
- Plumbing
- Sink
- Fridge
- Stove
- Propane tank
- Seats & beds
Electrical System
For ignition, charging and related electrical, please refer to the Engine section above.
- Instruments, radio
- Windshield wiper & washer
- Lights
- Accessories (inverters and such)
- Wiring, connections, and ground locations
Modified, Restored, Rebuilt Vans
- Various modified vans
- Various builds
- Various restorations
- Various rustorations
Camping & Traveling With Your Van
- Packing & Organization
- Gear & Equipment (general info, coolers, fridges, solar, bedding/sleeping, kitchen/cooking)
- Interior/Exterior Set-ups & Accessories (mats, awnings, side tents, chairs, etc.)
- Camping & Traveling Tips
- Camping Topics (stealth, campgrounds, tin-top camping)
- Hot-weather Camping
- Cold-weather Camping
- Showers
- Modifications
##This thread is locked. If you have topics you wish to be added to the FAQ, PM them to a moderator to have them added.##
Last edited by kamzcab86 on Thu Mar 22, 2018 12:15 pm; edited 74 times in total |
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kamzcab86 Samba Moderator
Joined: July 26, 2008 Posts: 7893 Location: Arizona
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Posted: Fri Aug 31, 2012 2:03 pm Post subject: |
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►Engine, Cooling, Fuel, Exhaust, Ignition, & Electrical
(For conversion/swap info, see next section/post.)
■General info
Gasket Identification
Vacuum leaks: What/where to check - v.1
Vacuum leaks: What/where to check - v.2
Cleaning the engine - v.1
Cleaning the engine - v.2
Stigma attached to WBX?
Timing
Rod bolt failure!
Breather hose collapse
Cleaning the ISV
Fresh pistons and engine break-in
Crankshaft end play
What is this mystery plug in the engine bay?!
2.1L DJ engine specs/info
Building the WBX engine:
What gaskets go where
Building a 2.2
2.1 or 2.2 in a 1.9 case
Pics of a WBX build
2.1 rebuild
Performance WBX motors
Supercharging a WBX
■Cylinder heads & valve drive (15)
Head gasket replacement
GoWesty heads
Ratio rockers for the WBX – v.1
Ratio rockers for the WBX – v.2
Collapsible Pushrod Tubes for the WBX – v.1
Collapsible Pushrod Tubes for the WBX – v.2
Hydraulic lifters:
Clean / Bleed Lifters
Bleed/Clean Lifters 2
Official WBX lifter/tappet clatter thread
Noisy valves/lifters – v.1 (locked; use official thread)
Noisy valves/lifters – v.2 (locked; use official thread)
Noisy valves/lifters – v.3 (locked; use official thread)
Adjusting hydraulic lifters
Bleeding lifters!
■Lubrication system (17)
OEM oil cooler seal replacement
External oil cooler – WBX
External oil cooler – air-cooled engines
Vanagon External Oil Cooler Install - Rear Fender
Oil pump:
Oil pump install
Oil pumps
Engine oil:
Official Vanagon Oil & Filter Thread 2.0
Official Vanagon Oil & Filter Thread - locked, please use updated topic above
Official air-cooled Vanagon oil discussion thread
Official Vanagon oil weight/grade discussion
Synthetic oil discussion
ZDDP levels discussion
All other oil threads will be locked!
Oil Pressure:
Pressure sender photo (at end of thread)
Idiot light woes – v.1
Idiot light woes – v.2
Low oil pressure links
Oil pressure-related rod bearing failures
2.1-specific oil pressure questions
Dynamic oil pressure testing
Another pressure thread
Problems:
Stripped oil drain plug head
■Cooling system (19)
Problems:
Consolidated cooling system topic listing various problems and solutions
Rebuild your Temperature Gauge
Radiator fan won't shut off
Radiator fan won't turn on
Overheating
Radiator fan fuse getting hot
General info:
Coolant Flow 2.1 system, New Diagrams (12/2020) both Hot and Cold
Adding toggle switch to control radiator fan
Can you hear your low-speed fan?
Filling the cooling system:
Coolant/anti-freeze recommendations
Coolant/anti-freeze colors
No mess system bleeding
The Libby Bong
Cooling system flush and bong fill
Coolant pipes:
Stainless coolant pipes – pt. 1
Stainless coolant pipes – pt. 2
Stainless coolant pipes – pt. 3
Stainless coolant pipes - pt. 4 ("don't use 'em")
Stainless coolant pipes - pt. 5
Hoses:
Thermostat housing info
Alternate cooling hoses
Blue silicone replacement hose
VW to NAPA hose conversion chart
Cadillac radiator hose for '84 Vanagon
NAPA hoses for early Vanagons
NAPA hose replacement for 1.9L
Hose clamps
Subaru cooling system with Burley pipe
Leaks:
Subaru stop leak
Subaru coolant conditioner warning
■Fuel system (20, 23, 24)
20) Fuel Supply:
Replacing fuel lines - VERY IMPORTANT - A "MUST" READ!
E10 (Ethanol) Gasoline and the WBX - v.1
E10 (Ethanol) Gasoline and the WBX - v.2 (locked; use topic above)
Which brand of fuel do you use? - v.1 (locked; use topic below)
Which brand of fuel do you use? - v.2
Which octane to use?
87 vs. 93 octane
Gas mileage comparisons
Pressure testing
Fuel line clamps
Nice pictures of hoses and clamps
Replacement fuel rails: GoWesty vs. Van-Cafe vs. others
Fuel rail fix
Alternate fuel pump
Alternate Ford / Napa fuel pump and others
Fuel pump kill switch
ECU chip tuning - Look for links
Vent tube repair
Syncro fuel tank removal & reseal
Installing Megasquirt Injection on a 2.1
Installing Microsquirt Injection
installing new wire terminal on the oxygen sensor
Fuel tank/fueling issues:
Repairing a sticky/stuck gas cap lock cylinder
Vanagon doesn't trip the fuel pump auto-shutoff in time
Overfilling at fill-ups
Gas filler neck burps during refill
Fix for Fuel Tank Burp
Leaking fuel during & after fill-up
Finding a puddle of gas under your van
Fuel tank leaks
Gas smell after fill-up
Gas smell after fill-up v.2
How does the 2WD filler neck attach to tank?
Replacement gas tank review
Gas tank vents
Fuel tank re-seal
24) Fuel Injection:
DIY diagnostic tool for Digifant (no run/no start situations)
MAF and FI part interchange
Replacing injector connector
Aftermarket injectors for 1.9 and 2.1
Install a FUSE for the fuel injection system
Wiring and connectors
TPS adjustment
Air-flow meter (AFM) adjustment procedure ~ Digifant
Troubleshooting rich/lean conditions ~ Digijet/Digifant
Troubleshooting stuck open ICV/ISV (high idle)
Idle Control Module issues (high idle) & cheap fix
Throttle Body (TB) fixes:
JB Weld fix for worn out TB
JB Weld fix – pt. 2
Throttle switch
■Exhaust/emissions system (26)
Problems:
Failed emissions
Breather Tower operation and problems
General info:
Cleaning exhaust piping - v.1
Cleaning exhaust piping - v.2
Tuned exhaust for the WBX
Fitting an aftermarket stock exhaust
Generic Bosch O2 sensor
3-wire heated O2 sensor for vans up to 1985
Testing the O2 sensor circuit ~ Digifant
Testing the O2 sensor circuit ~ Digijet
Replacing charcoal in vapor canister
Charcoal canister replacement
Acorn Nuts on Exhaust Studs
■Electrical: battery, alternator, ground locations (27)
Battery:
Your van takes a Group 41 battery right behind & under the passenger seat.
You can place an auxiliary battery, if not already equipped, behind/beneath the driver seat; see below.
Ground locations:
1.9L vans
2.1L vans
Alternator:
Rebuild the Voltage Regulator
Inexpensive alternator regulator/brush set
High output alternator for a Subaru conversion
Adjustable regulator
Subaru conversion alternator light
Make Your Own Alternator to Starter to Power Terminal Wire
Alternator bracket: stripped mounting holes
Alternator bracket: broken mounting studs -v.1
Alternator bracket: broken mounting studs - v.2
Alternator bracket: broken mounting studs - v.3
Alternator bracket: broken mounting arm
Alternator bracket: modifications for reinforcement
Auxiliary battery:
Auxiliary Battery, Solar, & Accessory Setups: Pictures & Diagrams
Aux battery install
Another aux battery w/ pix
Biggest aux battery in stock location
Aux battery setup
Weekender aux battery relay wiring
Aux battery, microwave, inverter, & lighting install
Portable Power Packs / Solar Generators
Solar panels:
Solar panels to fit Westy luggage rack
Costco solar panel
Solar panel advice
Going Solar ~ incorrect topic number; bad link
More solar panel discussion topics
Power distribution:
Moving accessory power from main battery to aux battery ('86-'91 Vanagons)
Good Yandina wiring diagram
12 volt accessory outlets - Where are yours?
House Battery, Yandina, Xantrex & Atwood Install
USB port power:
Topic #1
Topic #2
■Ignition system
Problems:
No start, no headlights, no blower fan, & no wipers: Ignition switch and/or X-relay
No start, but power to accessories & fuel pump: Ignition switch, bad ground connections, faulty starter and/or connections, and/or park-neutral switch (A/T only)
Starter engages, but after a slight delay: Most likely faulty ignition switch
DIY bypass tool for diagnosing no-start condition
Cranks, but no start: no spark v.1
Cranks, but no start: no spark v.2 (faulty Hall sender)
Cranks, but no start: no spark v.3 (bad ground)
Cranks, but no start: no spark v.4 (faulty tach/oil pressure warning wiring at instrument cluster)
Cranks, but no start: spark
Cranks, but no start: Air-cooled
No crank, no start
Slow crank & no hot start
Intermittent no start
Starts then dies
Hot start: what is it?
Hot Start problem: 1985 1.9 Vanagon
91 Westy: intermittent high idle/hot start problems....
Hard start in hot weather
"Hot start" problem with a twist
No Start, Add +12v wire
Test Hall Sender, Make Tester
Set Ignition Timing
General info:
Replacing & testing ignition switch ~ DIY Guide (PDF)
Key-in power (Su circuit) not shutting off -- fixing the problem
Engine mystery plug
Installing push-button ignition switch
Distributor (dizzy) rebuild
Hall Sender/generator R&R ~ Digifant
Starter:
High torque starter overhaul
Bosch vs. high torque starter
Park-Neutral safety switch cleaning and adjustment
Last edited by kamzcab86 on Thu Feb 10, 2022 10:56 am; edited 71 times in total |
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kamzcab86 Samba Moderator
Joined: July 26, 2008 Posts: 7893 Location: Arizona
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Posted: Fri Aug 31, 2012 2:14 pm Post subject: Body (Interior, Exterior) & HVAC |
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►Body (Interior, Exterior) & HVAC
(For camper-specific equipment, see next section/post.)
■General information: dimensions, weights, paint, modifications, etc. (50)
Dimensions:
Van Length: 181"
Van Width: 74"
Van Height: height will vary between vans due to suspension, load, tires, etc.; generally speaking: 77" (2WD tin-top); 81" (2WD w/ pop-top); add 2" to those if 4WD
Vanagon & Westy dimensions/measurements
Sinka & Doka dimensions (metric)
Lower grille opening: 27½" X 6-3/8"
Volume: 17.78 cubic meters (627.84 cubic feet) - 2WD w/ pop-top
Pop-top: Yes, all are the same and are interchangeable
Westy beds: 45” X 74” (downstairs); 47” X 72” (upstairs)
Westy tables: 16¼" X 24¼" (front); 16¼" X 31-7/8" (rear)
Westy table leg diameters: 1.25" (early); 1.375" (late)
Sinka/Doka rear window dimensions
Engine dimensions
Weights:
Shell: 1375 lbs. (624 kg)
GVWR & curb weights ~ external link
Curb weights - v.1
Curb weights - v.2
2.0L engine: 300 lbs. (136 kg) - complete engine
1.9L engine: 287 lbs. (130Kg) - complete engine
2.1L engine: 350 lbs. (159kg) - complete engine
Manual trans: 91 lbs. (with oil)
Westy fridge: 30 lbs. (w/o door)
Westy upper bed weight limit
Protection:
Body cavity protection using factory/aftermarket preservative (cosmoline, etc.) ~ official VW literature
Corter van restoration - body and component protection/preservation
To bra or not to bra? - v.1
To bra or not to bra? - v.2
Which bra?
Painting & Restoration:
Door handles, etc...
Ideas
Emblem repair
Best products for plastic restoration
Using rust converters on parts and seams
Body repair manual
Rust worms:
Where you might find rust
Dealing with rust
Replacing side panel sheet metal
A rustoration
Modifications:
Adding grab handle to driver's side A-pillar - installation details
Adding grab handle to driver's side A-pillar and above front doors
Modifying the firewall for extra storage (2WD) - v.1 ~ no longer exists, use topic below
Modifying the firewall for extra storage (2WD) - v.2
Utilizing storage space under the floor (adding under-floor storage box)
DIY spare tire/clamshell storage container
■Hoods/lids ~ rear hatch (55)
■Doors (57, 58 )
57) Front doors:
Front Door Differences
Keyless door lock installation
Power window motor rebuild
Door handle disassembly
Interior rear hatch release/latch
Power door lock repair:
Power door lock fix ideas - v.1
Power door lock fix ideas - v.2
Power door lock fix ideas - v.3
Power door lock fix ideas - v.4
Power door lock fix ideas - v.5
Power door lock fix ideas - v.6
58 ) Rear (sliding) door:
Sliding door maintenance
Sliding door horizontal roller bearings
1985 ^ Sliding Door Alternative Rollers/Bearings
Early sliding door handle fix
Extending slider door hinge
UHMW Tape: Quieting the slider door + others
Sliding door hinge repair rebuild
$11 Sliding door screen (with photos)
Adding grab handle to inside of sliding door
Sliding door handle re-keying how-to
Modifying New Style Sliding Door To Fit Older Van
■Sunroof (60)
■Tarpaulin (61)
Doka/Sika tarpaulin/canopy suppliers
■Bumpers (63)
Bumper end cap repair
Remove Rear Clad Bumper, Carat GL
■Glass, window regulators (64)
Window insulating blankets/curtains
Windshield, front door windows:
Windshield sealant
Removing windshield and repairing rust
Removing/installing front door glass
Replacing manual window regulator
Manual regulator cleaning & lubing
Tightening the vent window
Repair Vent Window Mount
Side and rear windows:
Slider window rattle fix with pics
Adding opening rear side windows
Later rear window vents
Replacing rear window vent material
Installing jalousie windows into a Vanagon
Power windows and other gremlins:
Power window stuck down
Adding power windows & locks
Rebuilding power window regulators
Replacing power regulators with manual regulators
Replacing power regulators with manual – pt. 2
Budget window switches
Rewinding questions with pictures
Promex Italian aftermarket electric winders
■Exterior ~ accessories, side moldings, mirrors, grilles, etc. (66)
Curing floppy mirror syndrome ~ manual mirrors, v.1
Curing floppy mirror syndrome ~ manual mirrors, v.2
Curing floppy mirror syndrome ~ power mirrors
How to retrofit power mirrors
How to install LT mirrors
Subaru mirrors on a Vanagon
Jeep Wrangler mirrors on a Vanagon
DIY truck mirrors
List of replacement mirrors
Side steps
Alternative grille emblems
Decal files
■Seat belts (68 )
Installing 3-point rear seat belts
Adding 3rd rear lap seat belt & GoWesty shoulder belts to a Westy
Seat belt anchoring
■Interior: trim, accessories, etc. (70)
Dash removal
What else to do while replacing a front heater core - Dash is out in this case!
Installing a Weekender interior with Z-bed and table
Show me your interiors!
Flooring:
Wood flooring
Carpet & flooring options
Replacing the carpet: Should I stick with OEM?
Westy carpet replacement options
DIY cheap OEM floormats
GoWesty rubber floormats
Rubber floormat for a passenger van
VW carpet floormats
Consoles:
Deluxe Dash Console/Gauges/Heater Core Project
Deluxe dash console
Center console concept...and cup holder ideas
GoWesty center console
Center console ideas
Rhino Consoles-brand center consoles
Cup holders:
Dash-mounted CJ5 grab bar with cup holders and other accessories
Center console with cup holders
How to replace Multivan/Weekender cup holders
Where to mount flip-down cup holders? - v.2
Where to mount cup holders? - v.1
Cup holder options from other vehicles
Rear seat cup holders
■Seats (72)
Problems:
Rear seat won't unlatch
Alternative front seats
town and country stow and go 2nd row seats
General info:
How to remove front seats
Installing lumbar support
Installing bolt-on swivel seat base
Installing Carat-style jump seat
Installing Porsche seats
Installing Recaros
Installing Eurovan seats into Vanagon w/ pix
Installing Eurovan seats w/ pix – pt. 2
Seat rebuilding, cleaning and heaters
Passenger Seat Reclining Mod
Arm rests – disassembly and reassembly
Installing headrests into rear bench seat
Swivel Seat Base + link to Piano Hinge Mounting
■Seat upholstery, heating element (74)
Installing heated seat inserts
■Heater/ventilation (80)
Curing Hot Foot Syndrome
"Quick" vent flap repair
Cable mod
Replacing front heater core – with movies!
$50 "perfect" heater core search
$50 heater core – pt. 2
Front heater assembly
Rebuilding the front heater box with pictures
Heater core replacement
Heater removal issues
DIY cold weather front heater solution
Ford heater valve
Reseal OE VW Heater Core Plastic Tanks
Front heater fan:
Front blower motor rebuild with pics
R&R'ing front blower motor
Front blower motor replacement
Lubricating heater fan – Mullendore Port fix ~ original topic (locked)
Lubricating heater fan – Mullendore Port fix ~ continued discussion
Blower fan resistor
Blower fan resistor: Retrofitting/installing a (inexpensive) Jeep resistor
Rebuild blower fan switch
Rear heater:
Pictures of EVIL rear heater repair
More EVIL rear heater
Verbose rear heater repair
Rear heater core option
Removing rear heater: plugging the hoses/removing the T-fittings
Removing rear heater: plug or connect the hoses?
Rear heater hose restrictor
Alternate heaters:
Propex heater install locations: Pros and Cons
Installing Propex - dead photos
Installing Propex in rear cabinet
Installing Propex under rear seat - dead photos
Installing Propex under/in place of fridge - v.1
Installing Propex under fridge - v.2
Propex issues
Installing Atwood furnace
Additional aux heater info in the camping FAQ
■Air conditioner (87)
Converting your A/C system to Redtek - Great thread!
Rebuilding the "Older" A/C systems, upgrades: hoses, condenser, etc.
Rebuilding the newer "D" Pillar Controls Rear A/C
Compressors: Sanden 508 vs. Sanden 709 vs. aftermarket
Universal front A/C units
Westfalia A/C vents & removing plenum
A/C condenser replacement
Removing evaporator from a Westfalia
Adding second A/C zone
Fix That TinTop Duct Work!
A/C Electrical Fires in the "D" Pillar
PMW A/C Blower Fan Speed Control
Front Over Head A/C links
Westy A/C Intake Filter
Behr A/C Information
■Insulation, sound-deadening, odors, and rodent problems
Sound-deadening
Sound deadening – pt. 1
Sound deadening – pt. 2
Sound deadening – pt. 3
Sound deadening – pt. 4
Sound measurements
Sound-deadening comparison video
UHMW tape to quiet slider door and other noise spots
Insulation
Insulation & flooring pics
Transmission tunnel insulation – dead photos
Re-insulating engine lid
Re-insulating engine lid – pt. 2
Odors
Getting rid of "smelly van"
Rodent Problems
Plugging mice-accessible holes in your van
Mice prevention tips
Squirrel repellent methods
Mice entering van when camped - v.1
Mice entering van when camped - v.2
Mice in A/C cabinet
Dead mouse in vent system
Dead mouse in water tank
Cleaning up after mice infiltration
Damage a mouse can do: Chewed wiring, plastic, insulation, etc.
Last edited by kamzcab86 on Mon Feb 15, 2021 4:25 pm; edited 52 times in total |
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