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ftp2leta Samba Member
Joined: October 11, 2004 Posts: 3271 Location: Montreal
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Posted: Sun Mar 27, 2011 6:48 am Post subject: Vanagon maintenance (1983-2011) |
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Gentlemen, please comment and add stuff that I may forget. Bookmark this thread, I won't repeat mysefl twice, tired of doing so.
Source: Me, for the one who don't know me, I have been working on Vanagon ONLY for.... 6 years at the shop + 3 at home.
There should be more sticky here. too many coolant problem thread.
Any vehicle that was strong enough to pass the 20 years lifespan is due for major maintenance if you want some sort of reliability. A well maintain Vanagon can be damn reliable.
So if your buying a 25 yo Westy for your little family be ready to invest.
Here is the list to make your vanagon reliable.
Cooling system, part that need to be REPLACED!!!!:
-Radiator
-T-stat housing and T-Stat (2.1L)
-Coolant distributor (2.1L)
-all coolant hose around the engine.
-Long cooling pipe: Replace on 83-84 (metal) Inspect carefully on later plastic one in the back, especially the hot one on the right
-Heater valve in the front.
-Remove rear heater if possible.
-Water pump
TO BE REPLACE around the engine if your the cheap kind of guy (minimum replacement)
N, L, W, Y, Z, Z2, Z4.
Carefully inspect and sand blasted (or replaced but in general they can be fix) if you suspect that there is any sign of rust.
R, Q, Y, Z1, Z3
On late Vanagon, I think 89 +, the Z4 bleeder hose as a STUPID plastic nipple at the engine, it will crack!
Engine:
Minimum maintenance:
-Total reseal of the engine INCLUDING the head gasket.
-Head, well, REPLACE!!! Don't loose one cent on those old head.
-If your not consuming oil or very minimum consumption, don't mess with the pistons and sleeve.
-Fuel line....
http://www.benplace.com/fuel_line.htm
-Injector rebuilt and tested or new rebuilt one.
-Replace/rebuilt the classic: Alternator and starter.
-Belt
Fuel injection: Test:
http://www.benplace.com/fi_test.htm
REPLACE:
-OS sender
-Coolant temp sender (ECU)
-TPS switch (Inspect and adjust)
-S intake boot: inspect
-Distributor cap, plug and wire.... duh!
Clutch: Replace ALL part, transmission main shaft seal
Torque converter: Replace the seal and if you have money, rebuilt the torque converter (not a must)
http://www.benplace.com/vw_clutch_job1.htm
Drive axle: replace or inspect and re-pack.
http://www.benplace.com/cv_joint_maintenance.htm
4 speed:
-Replace master & clutch slave.
-Inspect clutch metal line from front to rear, especially over the spare tire. At the same time inspect metal brake line.
-Grease the shifter rod, form back to front
-Replace ignition switch
http://www.benplace.com/dash.htm
Automatic:
-Bypass the start wire in the shifter box! YES! join the to big red wire together.
-Ignition switch
http://www.benplace.com/dash.htm
-Adjust the Throttle body rod to down shift leaver (make sure the TPS switch is working)
Brake:
-Replace/inspect the obvious!!!
-Rear cylinder: REPLACE!!!!
-I would highly suggest a new brake master cylinder.
-Replace all 4 flex line at each wheel, you won't believe the difference in braking power.
-Inspect metal line, especially at the rear and over the spare tire.
Suspension
-Inspect upper table bushing (2 each side)
http://www.benplace.com/85rouge/rouge5.jpg
-The rest will never leave you stranded
Steering:
-Upper ball joint, replace both side, they are cheap$
http://www.benplace.com/85rouge/rouge7.jpg
-The big job:
BUT NOT A MUST!
-Power steering line: inspect, replace for flex one if to rusted.
-Wheel bearing, replace at least the front one (IN the brake disk)
Fuel delivery:
-REPLACE THE FUEL TANK and all seal, it's the cause of so many problems:
-Replace fuel filter AND pump:
So, you still think your van is reliable?
Of course this is a lot of money and time. You could at least use that list with your mechanic, as a guide. Do stuff slowly.
You think it's to much? Well, when at 3000 miles from home I don't rely on luck and I don't believe in luck. The vanagon can be very reliable but it as a price.
If anyone here (someone I know) would care to edit my English I would be glad to give him my user and password.
This is a serious thread, please stay polite. Add some constructive stuff. Price for part, availability, trick & tips that you may find useful for others.
I perfectly understand that some people (I understand but don't get why) are on a budget, still, there is minimum stuff that need to be done. For those with big long trip ahead... be ready to spend money.
Picture & video is the way to go.
Cheers, Ben _________________ Working with rust, grease, dirt and dust is a sad truth.
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FI part for sale: http://www.benplace.com/parts_sale1.htm
My site: http://www.benplace.com/vw2.htm
Subi conversion: http://www.benplace.com/vanaru_eng.htm
Youtube http://www.youtube.com/user/ftp2leta |
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candyman Samba Trout Slayer
Joined: December 20, 2003 Posts: 2694 Location: Missoula MT
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Posted: Sun Mar 27, 2011 7:08 am Post subject: |
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But Ben i want to spend my money on SA grill, 15 in gowesty wheels, recaro seats, big bumpers etc... Won't that be money well spent over silly brake lines?
Seriously, I agree with all the above and if any newbies or oldies, have not crawled over every sqaure inch of your vanagon, do it now!
Nice write Ben |
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dbean Samba Member
Joined: July 30, 2010 Posts: 36 Location: Nashville
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Posted: Sun Mar 27, 2011 7:56 am Post subject: |
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Thanks, great post! may help me with my coolant issue. |
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Corwyn Samba Member
Joined: December 29, 2009 Posts: 2238 Location: Olympia, Washington
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Posted: Sun Mar 27, 2011 8:28 am Post subject: |
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STICKY A great refrence for new owners. I think a TIRE sticky would be good too. I'm full of good ideas . . . _________________ '90 White Westy ("The Longship")
FAS Gen V 2.0
The Annual Baja Rally
https://www.thesamba.com/vw/forum/viewtopic.php?t=604813&highlight=baja
"If anything's" gonna happen, it's gonna happen out there"
~ Captain Ron ~ |
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eeebee Samba Member
Joined: July 17, 2009 Posts: 431 Location: Tujunga
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Posted: Sun Mar 27, 2011 8:36 am Post subject: |
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How about cleaning your grounds, replacing the ignition switch, and adding headlight relays. |
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carterzest Samba Member
Joined: January 22, 2008 Posts: 3842 Location: Eagle, ID/Sun Valley, ID
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Posted: Sun Mar 27, 2011 8:41 am Post subject: |
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Nice job Ben and definitely Stickylicious _________________ Happiness=Portland, Oregon in the rearview mirror! |
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Californio Samba Member
Joined: May 17, 2007 Posts: 1306
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Posted: Sun Mar 27, 2011 10:19 am Post subject: |
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It might be worth separating out the true show stoppers from the good-to-do maintenance items.
In the show stopper column I'd add the hall sender with its tiny tiny wires which can break and leave you calling for help at the end of a lonesome road, that is if you have cell coverage, and if not get on your walking shoes. |
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noganav Samba Member
Joined: January 06, 2006 Posts: 1236 Location: San Diego CA
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Posted: Sun Mar 27, 2011 10:36 am Post subject: |
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Excellent information, and a nice summary. Thank you. _________________ Westfalia Travel Resources Collaborative Map - Please add your favorite places!
http://bit.ly/westymap |
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DAIZEE Samba Member
Joined: January 26, 2010 Posts: 7552 Location: Greater Toronto Area Ontario West Side
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Posted: Sun Mar 27, 2011 10:49 am Post subject: |
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Ben, you could put together a BENI'S BOOK and publishing it, ever thought about it. You already have so much of it online. I'd think about it seriously. Not to be confused with a Bentley it could be BRIGHT RED! Seriously. THANKS _________________ '09 2.5L Jetta 5 cylinder, 5 spd, super turbo, see thread in H2O Cooled Jetta, etc...
83.5 Vanagon L Riviera Model with 98 1.9L TD AAZ 4 speed Daily Driver 3 out of 4 seasons (sold)
84 Vanagon GL Wolfsburg Westy WBX 4 speed (sold) |
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edgood1 Samba Member
Joined: September 30, 2004 Posts: 2049 Location: Plymouth, MA
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Posted: Sun Mar 27, 2011 11:34 am Post subject: |
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holy hell!
We need to link to this post EVERY TIME someone asks the question.
fantastic post, possibly the best ever to this forum. well done.
now we just need to post a parts list and price for "all of the above"
_________________ 1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia |
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randywebb Samba Member
Joined: February 15, 2005 Posts: 3815 Location: Greater Metropolitan Nimrod, Orygun
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Posted: Sun Mar 27, 2011 12:38 pm Post subject: |
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Californio wrote: |
It might be worth separating out the true show stoppers from the good-to-do maintenance items.
In the show stopper column I'd add the hall sender with its tiny tiny wires which can break and leave you calling for help at the end of a lonesome road, that is if you have cell coverage, and if not get on your walking shoes. |
I agree, but there are really 3 levels:
A. the most important show-stoppers are the ones that stop the show by killing you...
1. rubber brake hoses (which can fail catastrophically and cause a no brake condition)
2. rubber fuel lines (which can cause the van to burn to the ground, possibly with you or others i it)
B. the the ones that will disable the vehicle (and maybe kill you by stranding you far from water, food or heat)
C. comfort issues that most likely will not disable the vehicle or are so progressive in their failure that you will surely catch them (perhaps some of the rubber suspension bushings would fit here)
thx again for this thread, Ben _________________ 1986 2.1L Westy 2wd Auto Trans. |
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SL1 Samba Member
Joined: December 17, 2010 Posts: 251 Location: Nova Scotia, Canada
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Posted: Sun Mar 27, 2011 1:01 pm Post subject: |
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THANKS BEN
excellent info - as usual _________________ Steve
1985 GL Westy - 'Bullwinkle'
1978 Super Beetle - 'Rocky' |
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randywebb Samba Member
Joined: February 15, 2005 Posts: 3815 Location: Greater Metropolitan Nimrod, Orygun
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Posted: Sun Mar 27, 2011 2:36 pm Post subject: |
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the other issue re replacing parts is that many new parts available now, tho expensive, appear to be worthless junk
e.g. I bought a new M/C from GoWesty and it rusted in just a few months _________________ 1986 2.1L Westy 2wd Auto Trans. |
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MakeFast Samba Member
Joined: January 09, 2011 Posts: 118 Location: Portland, OR
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Posted: Sun Mar 27, 2011 2:49 pm Post subject: |
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randywebb wrote: |
I agree, but there are really 3 levels:
A. the most important show-stoppers are the ones that stop the show by killing you...
1. rubber brake hoses (which can fail catastrophically and cause a no brake condition)
2. rubber fuel lines (which can cause the van to burn to the ground, possibly with you or others i it)
B. the the ones that will disable the vehicle (and maybe kill you by stranding you far from water, food or heat)
C. comfort issues that most likely will not disable the vehicle or are so progressive in their failure that you will surely catch them (perhaps some of the rubber suspension bushings would fit here)
thx again for this thread, Ben |
I support this division as well and thanks for the great post Ben. I will be redoing some of these soon.
It may be helpful as well to group them together like "Replace fuel lines, while down there it would be easy to do XXX" _________________ 1986 Vanagon Westfalia |
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Californio Samba Member
Joined: May 17, 2007 Posts: 1306
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Posted: Sun Mar 27, 2011 3:46 pm Post subject: |
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Agree with the three levels of importance.
Very useful thread. |
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PNWesty Samba Member
Joined: October 18, 2010 Posts: 138 Location: Seattle
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Posted: Sun Mar 27, 2011 3:57 pm Post subject: |
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Thanks for the info. Brake line replace added to top of Spring To Do list. |
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UNIBLONDER Samba Member
Joined: March 25, 2011 Posts: 15 Location: Southeast USA
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Posted: Sun Mar 27, 2011 3:58 pm Post subject: |
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I'm new here and thank you so much for taking the time to post this, especially for folks like me. Mine is a 1980 air-cooled (and while it doesn't fall in the year range you mentioned--but I assume much of this is probably across the board) I know that many of these things have already been done, but I'm going to double check)..Thanks a million. |
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ftp2leta Samba Member
Joined: October 11, 2004 Posts: 3271 Location: Montreal
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Posted: Sun Mar 27, 2011 4:13 pm Post subject: |
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edgood1 wrote: |
now we just need to post a parts list and price for "all of the above"
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I was ready to do so, just an average price, part, time for DIY and normal shop rate labor, but I Already spent 3 hours writing this.
Of course this is to much for the average owner and the 3 level thing is very interesting.
I did several van like mine, well 4, enough to have a good idea of what a total (and a bit crazy) rebuilt is.
I would appreciate if this thread would be a sticky.
I would edit this one every time good suggestions/tip appear.
Ben _________________ Working with rust, grease, dirt and dust is a sad truth.
------------------------------------------------------
FI part for sale: http://www.benplace.com/parts_sale1.htm
My site: http://www.benplace.com/vw2.htm
Subi conversion: http://www.benplace.com/vanaru_eng.htm
Youtube http://www.youtube.com/user/ftp2leta |
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bjrogers86auto Samba Member
Joined: March 26, 2009 Posts: 1375 Location: Halifax, N.S.
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Posted: Sun Mar 27, 2011 5:04 pm Post subject: Work |
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I think your site is the sticky Ben! I have been using it for two years now as a reference. I had pictures printed for the intake/fuel line rebuild. I used it for the driveline work. It's like the Wikipedia for Westy's!
Thanks for everything!
Brian _________________ 86 Vanagon GL Westfalia 2.1
18 Nissan Frontier Pro 4X
19 Honda Civic Hatchback
A little rudeness and disrespect can elevate a meaningless interaction to a battle of wills and add drama to an otherwise dull day. Calvin and Hobbes. |
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ftp2leta Samba Member
Joined: October 11, 2004 Posts: 3271 Location: Montreal
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