Bought 85 Joker Jubilee to drive home from Chile, now dead.

[joetiger]

[ben_in_bus]

Great questions and ideas.

I have the 5 speed gearbox in my garage, intact and non-functional.
It would be fun to diagnose with an expert what went wrong after the jungle rebuild...and even restore so I could get the 5 speed back in the van. Do you do this work? If not, do you recommend someone who does?

For additional closure:

The details of that adventure are chronicled here: http://jokersinjubilee.blogspot.com/

and mapped here: http://jokersinjubilee.blogspot.com/p/our-map.html

Take care,
Ben

[Sodo]

[jimf909]

Thanks for the update! Glad to hear that it worked out okay. Super-sweet calculator watch!
_________________
- Jim

[ben_in_bus]

Just to put closure on this thread...
The rebuild was successful and is detailed in a long-format post:
https://www.thesamba.com/vw/forum/viewtopic.php?t=587363
Enjoy the ride.

[Waldemar Sikorski]

Find another 1.9 case in good condition. You've been given this link before http://www.westfaliat3.info/html/westfalia_t3_jubilee_edition_j.html and according to the info the Jubilee came carbureted or injected so your engine isn't so unique.
I've found this:

[Wildthings]

[ben_in_bus]

Great thoughts.
There is an engine for sale here in Chile but it is a different model.
We have the 'DG' engine.
Thanks again!

[Vanagon Nut]

I quickly checked Brazil, Argentina Craigs list etc. There must be other online or publication resources; I was surprised to see so few VW auto parts listings. I imagine you've searched but would still suggest finding a set of case halves.

@ all. Would having a seller remove the case head studs prior to shipping be a bad idea? It would obviously reduce shipping container size but then how many sellers would risk snapping studs?

Just a few thoughts.
_________________
1981 Westy DIY 15º ABA
(VW Gas I4)

1988 Westy DIY 50º ABA

VE7TBN

[TequilaSunSet]

[ben_in_bus]

No explicit plans to flip...but just considering that as an option as we already have 2 cars at home.

[TequilaSunSet]

[ben_in_bus]

UPDATE - Mid-Feb 2014
All vehicle info at the start of the thread. Note: we aim to fix the van in Chile and drive back to the states.


Thanks everyone for the help some time back. Here is our current situation and a plea for advice.

Over the last month, we have done the following...
-removed the engine, shipped to Santiago to WB expert.
-engine disassembled, blocks sent to expert to remove head studs.
-expert machinists, one after another, have attempted and given up on extraction. we are now preparing to work with a 5th machinist

-in the meantime, I have done lots of other improvements to the van as suggested (fuel lines, brakes, cooling system, etc.).
-I flew back to the states and bought parts (engine rebuild and others).

Now I am in a situation where I am losing confidence that the extraction will be successful. Options are:
-keep waiting and hope for the best. get the studs out. do the rebuild
-find a used, similar waterboxer in Chile. rebuild it.
-ship in a rebuilt waterboxer from the states
-purchase and ship in a conversion kit (subaru or bostig).

I want to make the rebuild work for a number of reasons:
-I have already invested a lot of time in this
-I have already invested ~$600 in parts (and a flight) for the rebuild
-Our vanagon is rare (commemorative Joker Jubilee edition) and bringing it back to the states with an original engine would make it more valuable in resale.

Is sentimentality preventing me from realizing that the engine can't be fixed?
Should I persevere and keep working with machinists to extract the studs?
If no...what is the best step forward to you?

Thanks!
Ben

[CdnVWJunkie]

Strange to see a twin barrel carb. I had a carb'd 1.9L in a DoKa years ago. It was a revised version of the Pict 34 as seen on late Beetles.

[Vanagon Nut]

.... and I will learn to count the images better.

Carb rebuild parts **might** have interchanges with other VW carbs. Not likely, but if need be, you might find a resource for this? Just thinking ahead to parts availability.

Do any of the Bay buses use a Pierberg carb? I know the older engines used Solex carbs.

Neil.
_________________
1981 Westy DIY 15º ABA
(VW Gas I4)

1988 Westy DIY 50º ABA

VE7TBN

[ben_in_bus]

Great ideas. I will certainly do the electrical clean-up.
I will number my photos to make responses easier.

[Vanagon Nut]

the coolant going to part on carb likely has to do with the choke. Yes. Searched "vanagon Pierberg carb image" and found info. i.e.

http://onemanspanner.wordpress.com/2011/06/13/pierburg-2e3-on-a-vw-vanagon/

http://www.gowerlee.dircon.co.uk/2E3type.html

double check against model # of yours.

Did you keep the carb? (rebuild, reseal time?)
_________________
1981 Westy DIY 15º ABA
(VW Gas I4)

1988 Westy DIY 50º ABA

VE7TBN

[Vanagon Nut]

Hi Ben.

Part between alt. and dist.: fuel pump. (edit) Part in RH of 12th image has an oil pressure switch and oil line so may be meant for an oil pressure gauge. Small hoses not connected at air filter are likely for the EVAP charcoal filter valve.

There appears to be two coolant temp senders. One in middle of image two and one in lower RH of image 9.

I'd suggest doing a visual inspection of wiring with electrical tape over it. This may be low on the list of things to do but worthwhile if the tape is easy to get at.

If you search clutch, transmission, or bell housing here, you should find info on some clutch housing checks you can do.
_________________
1981 Westy DIY 15º ABA
(VW Gas I4)

1988 Westy DIY 50º ABA

VE7TBN

[ben_in_bus]

Thanks again for all the useful ideas and advice. Absolutely...during the rebuild I will focus checking, cleaning, improving many of the other systems.

A quick update:

-Yesterday my local mechanic helped me remove my engine. The process was fast as we had an opportunity to ship the engine to Santiago for a very low price...if we could get it out, boxed and to the truck in ~3 hours. We did it and there was only one ground bolt that broke located on the left head.

-The engine is now boxed and on its way to Santiago to be rebuilt/sealed by an experienced waterboxer mechanic.

-During the dismantle, I became increasingly concerned about getting it all back together again as the engine (as many are) appears quite different than the ones in the Bentley. Because my engine is the euro-factory carburetor (25? Pierberg), I have no reference to tell me if everything is done right. Does anyone know where to get manuals for carbureted vanagon engines (esp. online)? All this said, I am sure there are some customizations that were done (wires that do not connect to anything...) And what is the pump(?) between the oil tower and the distributor?

-I know the best thing is to just put this back together in the same manner as when I took it apart...but I worry that some of the existing system if a little slap-shot and I want to trust in the system. Any advice for improvements are welcome.

Here are a whole slew of engine photos to discuss:

Engine Overview after leak, but before dismantled.
Photo #1

Here are four images that are closer-up on the pre-dismantle engine.
Photo #2

Photo #3

Photo #4

Note large airfilter and two strange disconnected tubes in the elbow between filter and carb cover. What were these for?
Photo #5

First image during dismantle
Photo #6

Further dismantled:
Photo #7

Photo #8

View of left side of engine. Note that the temp gage sender is disconnected and there is no place for the temp sensor as shown on the Bentley cooling diagram 19.8.
Photo #9

Further dismantled:
Photo #10

Carb from above. The mechanic suggest the choke did not look like it was working and there were a few wires that were not connected to anything.
Photo #11

Location of sheared bolt. What is tubing and device in lower right? Also what is device between oil tower and distributor? Coolant pump/thermostat for carb? That was all it connected to.
Photo #12

Here is more cooling plumbing for the carb (?) Is this custom? It is pretty corroded inside and the temp sensor (?) looks rusted in. The upper, shorter flexible tube went into the carb. The lower, longer metal pipe looks like it connected down to the heat exchanger tubing.
Photo #13

End of transmission...looking good?
Photo #14

Thanks again to all that help. I am learning so much from all of you.

Take care,
Ben

[tristessa]