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insyncro 
Samba Member
Joined: March 07, 2002
Posts: 6536
Location: New York
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 Posted: Thu Dec 22, 2011 12:39 pm Post subject: Porsche 3.2 powered Syncro wiring meltdown |
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I am no stranger to Syncros or conversions.
I have maintained this one of a kind 3.2l Porsche powered Syncro for many years.
This is why I have been extremely detailed in my approaches to wiring and especially adding to the Vanagon wiring.
What is pictured is the Porsche sub harness that connects the alternator to all of the Porsche management of the engine.
The owner decided, against my advice, to wire a battery maintainer (Walmart version) to his main starter battery.
Without over charge protection built in, the cheapo trickle charger fried the battery, harness and alt.
Luckily the smoke alarm in his garage saved the van from being torched completely.
Please...I am long winded about safety and using quality parts often in forums.
I am sharring this to help keep vans running, driving and doing so safely.
This is an unfortunate example of how a $25 addon cost $5000 to fix  |
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offroad.
Samba Member
Joined: January 01, 2009
Posts: 197
Location: llanelli, s wales
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| Posted: Thu Dec 22, 2011 12:50 pm Post subject: |
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| ouch. never a pretty sight. could have been much worse though. |
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randywebb
Samba Member
Joined: February 15, 2005
Posts: 3196
Location: Greater Metropolitan Nimrod, Orygun
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| Posted: Thu Dec 22, 2011 1:13 pm Post subject: |
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have you evaluated the condition of the 3.2L's ECU/brain yet?
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1986 2.1L Westy 2wd Auto Trans. |
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insyncro
Samba Member
Joined: March 07, 2002
Posts: 6536
Location: New York
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| Posted: Thu Dec 22, 2011 1:17 pm Post subject: |
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| randywebb wrote: | | have you evaluated the condition of the 3.2L's ECU/brain yet? |
All wiring, ECU and alt were replaced with brand new from Porsche.
I also wired the dual battery system properly and added a much more heavy duty onboard charging system. |
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GBA 88West LA
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Joined: September 04, 2008
Posts: 1353
Location: New Hampshire
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| Posted: Thu Dec 22, 2011 2:10 pm Post subject: |
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some folks have to learn the hard way  
what a bite of humble pie, never go against doctors orders
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currently 88 Westy GL Vanaru 07 2.5 EJ25/AA Trans/oiling plates, 1.14 3rd-.77-4th |
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Zeitgeist 13
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Joined: March 05, 2009
Posts: 2076
Location: Cascadia
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| Posted: Thu Dec 22, 2011 3:21 pm Post subject: |
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That's a terrible mess for sure. Gotta say I'm a bit surprised that Porsche would run an alt as small as 90 amp in their rigs.
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--Casey
'89 Bluestar
"Endeavor to persevere" |
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BlackDogVan
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Joined: December 21, 2007
Posts: 856
Location: Vancouver Island
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| Posted: Thu Dec 22, 2011 5:41 pm Post subject: |
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| Zeitgeist 13 wrote: | | That's a terrible mess for sure. Gotta say I'm a bit surprised that Porsche would run an alt as small as 90 amp in their rigs. |
Why would a 2 seat sports car need a bigger alt?
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Gone but not forgotten - 1991 Carat - AAZ transmogriffied to mTDi.
Still addicted, looking for Doka... |
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Zeitgeist 13
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Joined: March 05, 2009
Posts: 2076
Location: Cascadia
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| Posted: Thu Dec 22, 2011 6:06 pm Post subject: |
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I guess I'm assuming the 3.2L versions had lots of electrical consumers, like AC, power peripherals and boomin' stereos, etc.
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--Casey
'89 Bluestar
"Endeavor to persevere" |
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edgood1
Samba Member
Joined: September 30, 2004
Posts: 1209
Location: Plymouth, MA
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| Posted: Thu Dec 22, 2011 6:52 pm Post subject: |
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| BlackDogVan wrote: | | Zeitgeist 13 wrote: | | That's a terrible mess for sure. Gotta say I'm a bit surprised that Porsche would run an alt as small as 90 amp in their rigs. |
Why would a 2 seat sports car need a bigger alt? |
the same reason that it needs a 250hp engine...its a porsche.
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1987 Syncro Westfalia powered by Subaru
1963 Sundial Camper |
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21-window
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Joined: March 23, 2004
Posts: 224
Location: out planting
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| Posted: Thu Dec 22, 2011 6:54 pm Post subject: |
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just out of curiosity. How is the 3.2 in a syncro?
I like it in my 911, but I'm not sure the cams are right for a syncro? |
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Christopher Schimke
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Joined: August 03, 2005
Posts: 3311
Location: PNW
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| Posted: Thu Dec 22, 2011 7:30 pm Post subject: |
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Man, what a mess. Sure glad it wasn't worse.
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Christopher
*Custom wheel hardware for Audi/VW and Mercedes wheels - Urethane Suspension Bushings*
T3Technique.com or contact me at [email protected] |
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wcdennis
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Joined: July 20, 2004
Posts: 278
Location: Winston-Salem NC
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| Posted: Thu Dec 22, 2011 8:21 pm Post subject: |
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| I'm a bit confused. Are you saying that a battery charger caused this melt-down? I don't think most chargers can deliver enough amperage to burn up cable like that. My guess would be a bad diode in the alternator that created a short circuit, but maybe there is something I'm missing. |
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insyncro
Samba Member
Joined: March 07, 2002
Posts: 6536
Location: New York
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| Posted: Fri Dec 23, 2011 9:14 am Post subject: |
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| wcdennis wrote: | | I'm a bit confused. Are you saying that a battery charger caused this melt-down? I don't think most chargers can deliver enough amperage to burn up cable like that. My guess would be a bad diode in the alternator that created a short circuit, but maybe there is something I'm missing. |
The cheap trickle charger had no overload protection...meaning, it charged the battery, cooked it and kept on charging, slowly heating up the wiring and alt until it melted and caught fire
I am just posting the pictures of the burned parts.
The owner is really embarrassed and is not a Samba member.
He asked me not to make a big deal out of it, so this is my post.
The 3.2 Syncro is an amazing vehicle.
The motor is from a 89 ragtop.
The cams are stock.
Transmission was regeared, I have never checked to see if the stock VW ring and pinions are still in the front diff and trans.
It drives very similarly to my SVX converted Syncros, BUT sounds so much better with an adapted aftermarket Porsche exhaust system.
Vroom, vroom. |
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insyncro
Samba Member
Joined: March 07, 2002
Posts: 6536
Location: New York
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| Posted: Fri Dec 23, 2011 9:16 am Post subject: |
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| Christopher Schimke wrote: | | Man, what a mess. Sure glad it wasn't worse. |
Me too.
I almost cried when he called.
I love this Syncro |
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D Clymer
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Joined: December 22, 2005
Posts: 2207
Location: Issaquah, WA
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| Posted: Fri Dec 23, 2011 10:29 am Post subject: |
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| insyncro wrote: | | Christopher Schimke wrote: | | Man, what a mess. Sure glad it wasn't worse. |
Me too.
I almost cried when he called.
I love this Syncro |
Hey Dylan,
Just out of curiosity, does his conversion use the old MSDS adaptor kit or were the parts custom fabricated?
Yeah, I've loved the idea of this conversion since seeing the old European Car article back in 1991 showing the MSDS Savannah Beige Syncro with 3.2 Carrera motor. As we've discussed, this engine doesn't make any sense these days given the rarity, age, cost, rebuild cost, and power output. But I once owned an 84 3.2 Carrera and the sound of that engine and the way it pulled from 4000 rpms onward were enough to send chills of excitement down your spine every time you drove it. If I could find the right buy on a known good engine, I would still do it.
Glad it's in the right hands and getting the repair attention it needs.
David |
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insyncro
Samba Member
Joined: March 07, 2002
Posts: 6536
Location: New York
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| Posted: Fri Dec 23, 2011 10:49 am Post subject: |
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I have seen the MSDS kit...this van is completely custom, one of a kind.
AFAIK, BenT has the last remaining uninstalled MSDS kit.
Anyway, ah the sound
Right on.
I have a youtube on my channel with a 3.6 motor in it.......out on a country road......shifting through the gears......nothing beats that sound |
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insyncro
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Joined: March 07, 2002
Posts: 6536
Location: New York
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AtlasShrugged
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Joined: October 30, 2008
Posts: 661
Location: Decatur, Ga. USA
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| Posted: Fri Dec 23, 2011 11:41 am Post subject: |
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Having worked on many 3.2s..it could of been the trickle charger..no question.
Those engines did have a problem with the harness coming from the alternator, inside the plastic harness sleeve where it exits tightly through the engine shroud. Over time with the exposure to heat the wires and insulators would crack causing a short or broken circuits. The big red alternator B+ is always 12v and could have shorted out causing the damage.
Problem was made worse by voltage regulators that overcharged too..very common. Fries the diodes, wires and the B+ grounds out. |
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insyncro
Samba Member
Joined: March 07, 2002
Posts: 6536
Location: New York
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| Posted: Fri Dec 23, 2011 11:58 am Post subject: |
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| AtlasShrugged wrote: | Having worked on many 3.2s..it could of been the trickle charger..no question.
Those engines did have a problem with the harness coming from the alternator, inside the plastic harness sleeve where it exits tightly through the engine shroud. Over time with the exposure to heat the wires and insulators would crack causing a short or broken circuits. The big red alternator B+ is always 12v and could have shorted out causing the damage.
Problem was made worse by voltage regulators that overcharged too..very common. Fries the diodes, wires and the B+ grounds out. |
Thank you for validating my concerns.
I appreciate knowing, although displeased it was common, as I replaced with factory new.
Are there better alts. that are a direct fit?
I wrapped the new harness with an additional layer of heat tape at the junctions of wires as I do with my Vanagon conversion harnesses. |
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SL12572
Samba Member
Joined: April 13, 2011
Posts: 218
Location: Washington
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| Posted: Fri Dec 23, 2011 12:16 pm Post subject: |
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| insyncro wrote: | | http://youtu.be/Fd6NMyyWYZM |
Just watching the video gave me chills when that engine started to sing...
Oh man oh man oh man....I want I want I want! |
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