Finish project started on 87 Westfalia: Bostig is going in

[JudoJeff]

Well, I requested my tune from Jim @ Bostig last week, and while waiting for it, fixed more electrical circuits. Jim was out of 'eye of newt'.

With the battery in, I found minor things not working. Most are the fault of old age and corroded wiring. I traced the wires back to where I had 12v, and ran new ones. The side marker light sockets were shot, so I added new ones.

The tune came in, but I had to wait for my neighbor who owns a Windows machine. (Insert Window OS rant here...) My first try failed, but the second went swimmingly. Much easier with the new info on the Bostig site! (I'm not someone who weaned on Windows, so I'm clueless.) I wrote out my notes, which I'll post on Bostig's site, and at the end of this, skip if you "know-all-that-stuff"...

Went over to the Westy, spoke gently to her so she wouldn't spook on me, and inserted the SCT device.

Programmed the ECU first attempt!

Fed her a carrot to calm her down, (she'd just been probed rather rudely!), then fired it up for the first time..... SUCCESS!!!!
You can tell by the smoke burning off the exhaust it's running....

I'd forgotten to tighten the cap on the power steering reservoir, so that made a big mess to clean up.

Now to get a datalog to send off to Big Jim.

These are the instructions you might want to skip over:

Downloading & Installing SCT Device Updater
Watch the video on Bostig, then here are my notes.

SCT is NOT plugged into the computer yet.
Go to: www.sctflash.com
Top of page, click on: “tech support”
Page down past product images to “don’t see your product”, click on it.
My X3 has a giant “3000” on the outer box, so I picked that one. They all look alike, so find the number....

You’ll see a screen, click on “update software”.
Two things will download.
SCT is NOT plugged into the computer yet.
there will be an .exe file in bottom left corner, left click on it.
SCT is NOT plugged into the computer yet.
On the desktop is a file: “XCT Device Updater”, double click on it.

This does it’s thing and a new screen appears.
“Automatically Check for updates”.
PLUG in the SCT device.
Click on the above choice.
(You may have been asked for the SCT’s serial number at some point, this was NOT the time to plug in the device, just the serial number off the back.)

Now, to the meat & potatoes- click on “load custom tune”
locate custom tune on the desktop, (GAJ2-v500......cef was mine)
click on file name, then “Add to device”.
You can change the name now, I picked “1987 tune”..[hours of thought went into that name!]
click on “Program”
Yeah, hope it worked for you!


Tune is in the SCT, move to reflash the ECU on the vehicle:

Plug SCT device into your OBDII port. sings a musical ...

All on the SCT screen-
“Program Vehicle” select
“Custom Tune” select
disclaimer select
“Key on, engine OFF” do it, then hit select
“Key OFF, engine off” do it, then hit select
“What custom tune to load?” select your tune
“Program with ‘your tune’s name’?” select

SCT does it thing, walk away, drink a beer, this is worse than waiting for a baby’s birth......

After the job is done, turn key off, now you get to do the first startup!
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[insyncro]

[rmcd]

Hey JudoJ
Thanks for taking time to post.

I noticed a hose that is fairly close to your muffler.

https://www.thesamba.com/vw/gallery/pix/1428568.jpg

Are you going to wrap the exhaust or pipe or both?
How close is too close for silicon pipes?
Thanks again.
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[JudoJeff]

Bit of an optical illusion in the photo. The hoses at the closest are 3 inches away. On my first conversion, I used protective sleeves over them, this one only has plastic loom. If the loom melts from the heat, I'll know it got hot. But I doubt there'll be a problem, even standing still, it gets a lot of air.

I wouldn't wrap the muffler, they rust faster than a Rambler, without adding a wrap.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[LemonCove]

[JudoJeff]

I sent in the data log, took me three tries. I have a short video of the engine idling, it purrs! No luck uploading that, either.....
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[Bassyaks]

Sounds like you need the Geek Squad

[JudoJeff]

bassysaks, I do! Windows OS is so oddly done, confuses me.

Nearing the end of this, maybe it'll sell in the next few days, people are coming over.

Once Jim gives the OK, will drive around on my street, and see what shakes out.
re-edit: He didn't! I goofed up how to set up the XCT. Two files are sent, one to tune the engine (reflash the ECU), and one to configure the XCT to do a datalog. That's the one I missed. Back to the drawing board....

Punchlist:
Brake lights are always on, I traced the wiring all the way back to the master, where one of the switches is stuck. Ordered in a new one. (Should have started on that end of the wire!)

New horn due in Friday, easy to install.
The only other electrical thing is the MIL light is always on, even with the key out.
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________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

Alright, now I need help. I've failed to transfer the config file to the SCT device twice. This is my kryptonite on these conversions....

Don't have a Windows machine, and have to traipse over to my neighbor's each time.

Talk to me like I'm a two year old, and maybe I'll understand.....

Edit on 11/27: Well, not as dumb as I look after all, the file was on the SCT, I just didn't know where to find it. So I'll try the datalogging again today, and see if the results are what Jim wants.

More editing: Just started it and now it's at 3000 rpm. Trouble code says idle air control out of adjustment, would that cause the high rpm? Going to have to pull the IAC and clean it.

Edit: Fixed by cleaning the IAC. Another "should have done this while the engine was out, bite me on the ass" thing.

Dataloging right now, wish me luck!

Edit once again: Datalogging worked but the IAC is flaky. I'll replace the IAC ASAP.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

Been pulling my hair out! (What's left up there, anyway...)

Replaced the IAC, still at 3k rpm. Re-did the vacuum hose connections, still at 3k...pestered Jim until he took out a restraining order, but from 100 feet away he told me to do the "Set Idle Stop" procedure, page 99 in the Bostig manual...

Started it up and it went to around 3500 rpm, then it stalled out. Re-started it, and the rpm went to around 1000 rpm. WTF! So started the datalogging, took over 45 minutes to be warm enough to allow the thermostat to open. At least I know the cooling system works well!

Never did figure out where the idle stop screw actually was-

Datalog sent to Jim, waiting with bated breath for his Holy blessings on a test drive......
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________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

Drove around the block, (literally, it's not registered!).

Datalog is done, but have to wait for the neighbor to be home.
Notes: Speedometer didn't work, will check to see if OP disconnected it. VSS works, so the Ultragauge would give you MPH.
Overheat light went on, that means air to be bled out of the cooling system, common with this job.
Shifts beautifully, much nicer than my '89.

(Without Jim's feedback,) I think there's still an air leak in the vacuum.

Mail arrived, no brake switch yet. I want to re-assemble the dash.
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________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

Well, Jim said there's a vacuum leak for sure. I replaced the vacuum line (3rd try is the charm?), now seems to idle better.

The water pump was weeping, so I popped a new one in. (Can't stand to see a girl cry....) (BTW, when you pull the pump, a few paper towels isn't enough.)

Speedometer cable is there, will have to pull wheel and see if it's connected.
PO's work on the brakes may have left it off.

I'm not convinced the thermostat is opening/closing, I used the SCT to monitor another idle test, then went over to the Ultragauge, which gives me better information. Radiator kicks on normally, don't see the T-stat doing its' thing.

If the mail today brings the brake switch, I'll install and test that circuit, then the electrical circuits will be finished. (Can't test the new horn until I re-assemble the dash.)
Edit: Switch arrived in a much too big box, installed no problem, horn beeps, brakes don't stay on, all electrical working!
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________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

For those of you following this build blog because you hope to install a Bostig in your vw, there's a Bostig conversion kit for sale in the want ads, with a 2003 Zetec for $4875. That's a VERY good price! Even paying shipping from CA!
(Remember, I bought just the kit from Montana, for a lot more $$$)

here's the link:

http://www.thesamba.com/vw/classifieds/detail.php?id=1866189

Let me know if you get it.
Edit on 12/2: READ comments below, I got this wrong.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[insyncro]

[JudoJeff]

Dylan,
I don't know which kit this is from but I could figure out how to make it work. Good point to mention, though, so that I don't lead someone astray.
Jeff
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[MsTaboo]

[Bassyaks]

Jeff, can't help with the SCT mine is different.
Connect the Valve cover hose to the air box, check you vacuum caps, also the brake booster connection. Recheck your throttle cable, maybe loosen it and see where the idle is.

[insyncro]

[insyncro]

BTW, your high idle is due to a terminated vacuum line from the valve cover.
It needs to be connected to the intake, so the the PCV will be able to control crank case pressure.

[JudoJeff]

Dylan,
First off, re-thinking about the kit, you're right, and I'm wrong, it's too old to be of use without a lot of effort. Smarter to buy a new kit with all the engineering wrinkles solved. (I'm done stroking your ego...)

"BTW, your high idle is due to a terminated vacuum line from the valve cover.
It needs to be connected to the intake, so the the PCV will be able to control crank case pressure."

Now I need you to explain this better. The cam cover hose right now isn't connected to anything, just hanging out looking for girls on the corner. Why would plugging it into the airbox make a difference? Or do you mean something else that I haven't noticed? The Ultragauge says the engine is in an open loop, so I know something's amiss. I'm about to spend the morning connecting up the speedometer cable (I hope), and looking for the vacuum leak. So any help is appreciated. (stroke, stroke)
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)