1991 Multivan TDI build

[macjack]

wow. good catch on the mounting bar. good that you didn't put any miles on that without repair/replacement.
btw, I kept an eye out for your van earlier this summer when I brought my family to the island and stayed at the Menemsha Inn for a few days. Didn't see it, unfortunately, but I have no idea where on the island you are. . .
_________________
87 TDI Syncro Westy
81 Westy (sold)
80 Rabbit Wolfsburg (rolled)
Bike as primary transportation

[newt3]

didn't know if someone told you already those dics for the link on your pic are in the wrong position!

if you drive them in wrong postion the link will break

here you see them correctly:

part no4

[Scottgb2]

So I just bought my first Westy this past June and just wanted to let everyone in this discussion thread know how much I have learned from reading through all the build/modification projects. Needless to say my van learning curve is nearly vertical at the moment!

My 84 has a Boxeer TDI installed by the previous owner in Maine. The drive from Maine down to Northern Virginia went flawlessly. That diesel just purred along and climbed up and over every hill along the way. No problem doing 70 mph. Funny though, not really interested in driving fast in the Westy, happy to roll along back roads at 50 rather than interstates any day...

Anyway, I'm looking forward to reading more about all the projects and travels posted by ya' all and hopefully contributing some useful (and fun) information to the group in the months ahead.

Cheers!

[Multiman mv]

[Multiman mv]

[Multiman mv]

[macjack]

[Multiman mv]

I finally replaced the serpentine belt yesterday. I was looking for a 16mm bolt on the tensioner like earlier versions but the version i have has a square knob on the top of the tensioner that makes for easy release of the tension from above the pulley without having to remove anything in front to gain access. Pretty simple. I just used a socket and a 1/2” extension bit to gain enough leverage to loosen the tension. The proper size open ended wrench probably would have worked even better. As you can see, the belt was fairly compromised. It probably would have lasted a bit longer but, it wasn’t something i wanted to take my chances on.

We were supposed to go to Vermont last weekend for a few days but because of the incident, I ended up delaying the trip. I had the temporary engine mount in place but really didn’t want to travel far, all loaded down with gear with a welded engine mount and a chafed serpentine belt. The new mount arrived after our ferry reservation so we ended up bailing on the trip. We are going to reschedule for sometime in September or early October instead.

Notice the wear from the belt kissing the carrier bar beneath. With the new engine mount in place, there is at least an inch and a quarter space between the belt and the bar. When the mount cracked, the engine dropped significantly. I’m lucky it didn’t drop further. One can only imagine the damage that could have occurred. With the new mount in place, the engine is back in its original position with plenty of clearance.

Tensioner release

_________________
1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[shagginwagon83]

How did the trim shine work out on the pop top? Still holding up? I spilt some alcohol on my white pop top while removing tree sap from camping
_________________
Brandon
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram @joannthevan

[Multiman mv]

[DuncanS]

Have you tried Penetrol? I know that when boat gel coats get dull, this is a technique the yards use. A season is all you get, but with wax on top, a couple.

Wow--A glass out paint job. That is my ultimate dream, but........... The engine swap, a rebuilt tranny, wheels and tires and I'll have in these alone way more than twice what I paid for the girl. And first there are some rust issues that need to be dealt with in any case. DS wheel surround seam. I've had these in the past and can speak from experience that in mid New Hampshire as a daily driver, 4 years from now this seam will need serious removal and rewelding, so I want to get that first. The other spots on the metal are just dirt. Not rust. Paint fine there.

Then there are two bad windows. The DS rear fixed where I took a dental pick and removed most of the rust from under the rubber and then epoxied and Rustoleumed. Holding, but obviously the gasket is compromised and water is probably still accumulating there, but behind the rubber and isn't visible.

Not too worried as in the next 6 months this fixed window will become an electric up and down conversion from a spare PS front window and regulator I have.

This photo below is the real bad one. Rear hatch. Need to pull the glass, reweld the bad area and use new gasket material. NOW! How this all fits in with paint is unknown. Front under windshield glass tin is badly sandblasted from 28 years of road crud being thrown up from cars in front. .

Sigh--Your Pippin looks so crisp and perfect in your posted photos, but I'm sure you worry about a few spots here and there. The main thing is to keep using and enjoying them. Have fun on your September jaunt.

Duncan

[Multiman mv]

So the van started acting up yesterday. A lack of power and if I accelerated quickly, I could hear a shrill whistling sound which almost sounded like a really loud turbo spooling up. I figure it was some sort of boost leak and went looking around the engine bay trying to find the culprit. I couldn’t find it on the first look. I ended up going back in for a second look and discovered that the hose clamp on the lower pipe coming off the intercooler had completely slipped off. Notice the spray pattern of oil residue coming from the lower hose location. It must have happened when the engine mount broke and the engine hinged downward on the passenger side. It must have loosened that connection and pulled at it. Finally it just slipped off due to the oil in the area. I retightened the fitting and the van is running as it should. Plenty of power, no noise and quick acceleration. I love an easy fix that even a guy that is mechanically challenged like myself can find and rectify.

_________________
1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[macjack]

Great work diagnosing and fixing that hose! Your hypothesis about the broken mount leading to a loosened connection makes perfect sense. Glad it’s back to its turbo diesel glory.
_________________
87 TDI Syncro Westy
81 Westy (sold)
80 Rabbit Wolfsburg (rolled)
Bike as primary transportation

[Multiman mv]

[ALstew]

Hello, I tried reading through your thread after the search function... How was the trans regeared? Are you running a 4.13 ring and pinion with stock gears? Or did you just regear 3 and 4 with a 4.57?

[Multiman mv]

[DuncanS]

You have done some great upgrades which all of us have followed and I'm sure many are using your advice.
By any chance are you watching: https://www.thesamba.com/vw/forum/viewtopic.php?t=722193 ?
I/we'd love to hear what your are doing about prevention and suppression. Not counting the obvious fuel lines and so on.
I'm concerned and need to add something besides the pitiful 2 3/4 pound Kidde.

Duncan

[ALstew]

[Multiman mv]

[Multiman mv]