Toxic fumes coming from dash

[Vsyevolod]

Hello gang,

I've been living in my van (88 Westy w/Ford Focus engine) this winter here in Seattle (brrrrr), and doing okay with it. This last week saw temps well below freezing. After sitting at a friends house on Whidbey Island for a few days I thought I'd start it up and run it for an hour just to recharge the battery, warm it up, etc.

Came back to turn it off after an hour and the van was filled with smoke, like a light fog. It smelled like electrical wire had burned, though it could have been something else. I found that I had left the front heater fan on medium and it wasn't working. I turned the fan off then on and it came back to life. It took all day to clear out the smell by leaving all the doors open. Even smells a bit the next day.

The smoke/fog was coming out of the front grill (ever so lightly) just off center on the passenger side.

The next day I drove it 70 miles back into Seattle and had to drive with the window down (in sub freezing temps). After arriving, I felt horrible. Headache, nausea, chest pain (though all of those symptoms were mild).

Today I tore into it. Thinking that it was electrical, I checked switches and the cigarette lighter in that area. Then I got to thinking it may have been from the front heater core. Though if the heater core is leaking, it should smell slightly sweet from what I understand (anti-freeze), and this definitely didn't. Still, my physical symptoms are strong enough that I think it might be that.

Since this happened in the middle of a cold snap, could it be the hoses going to/from the heater core? Am I better off just replacing the core? Core + hoses? And heater box clamps?

I can do most/all this work myself if all I need to do is remove the dash (3 hours). Any recommendations on what else it might be? Any thoughts on clamping off the hoses to the radiator to keep air out of the system? Anything else I might be missing? Oh, and I do have a shutoff installed in the pipe coming from the front heater core.

I did a search on "Fumes" with a couple other keywords and think I might be onto the problem.

Much thanks for helping me tackle this problem.

Stephen




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[Paulbeard]

Might have been the blower motor resistor, a big chunk of ceramic that sits inside the air box, right against the plastic, unshielded. The inside of mine was all bubbled and nasty from the heat so I opted for the dhaavers Jeep resistor swap. The switch itself might be a good starting point as well. Those old and thin wires don't get any less brittle with age and use.
_________________
Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs

[Vsyevolod]

Thanks Paulbeard,

Question, if it was the blower motor resistor, would it still create toxic fumes even if the blower motor were turned off?

And does this also necessitate removing the dash?

Stephen




.

[Paulbeard]

[maco70]

Stephen,

I experienced a fire from the dash and I just can tell to be very aware of that and I would say don't run the vanagon anymore until the problem is solve.

Hope it helps.

Good luck
_________________
Martin from Montréal

1986 Vanagon GL full camper westfalia
(brown/tan interior)

[IdahoDoug]

Smoky deposits and the scent of burnt plastic can continue to linger long after that combustion. To get rid of it may actually require some serious actual cleaning of the ducts (easy when dash out), and possible replacement of the burnt part of the plastic housing that's now scorched. Alternatively, when it's out there may be a proper paint to spray to top coat the scorched plastic and stop the smell. Ask an expert on that, as the last thing I'd want is for you to trade this smell for a few days of outgassing fresh paint. Some dry quickly.

Doug
_________________
1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[mikemtnbike]

[Gnarlodious]

Are you absolutely sure it isn’t vaporizing coolant from your heater element leaking?
_________________
Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[air-h2o-air]

a rodent in the heater box,ducts? or rodent that laid on the resistor?

[Vsyevolod]

[dhaavers]

Please consider: http://www.thesamba.com/vw/forum/viewtopic.php?t=623382

Result: Never worry about the <f'n> ceramic resistor again, plus it's ridiculously easy to
replace if/when your new resistor bites the bullet...(which they all do eventually)...

- Dave
_________________
86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[Gnarlodious]

There’s one wire which is full power to the blower, I don’t remember which. Its easy enough to hook up an external resisto on that wire, or better yet an electronic DC controller that can handle 15 amps.
_________________
Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[Paulbeard]

[dhaavers]

[IdahoDoug]

Stephan,

Many of us have used a foam product available at any local auto store called "RV weatherstripping" or similar. Comes in rolls and is very soft and often used between pickup beds and their caps. You definitely want auto grade. On reassembly, I did not reuse the plastic foam retainer things (look like a mesh flap).


Best, Doug
_________________
1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[wcdennis]

I know this is a long shot, but considering you symptoms (Headache, nausea, chest pain), which are also connected to exposure to carbon monoxide. I know, that having the engine in the back, makes it pretty unlikely--still, you might want to check it out, to be sure.