Hello! Log in or Register   |  Help  |  Donate  |  Buy Shirts See all banner ads | Advertise on TheSamba.com  
TheSamba.com
 
Vanagon maintenance (1983-2011)
Page: 1, 2, 3, 4  Next
Forum Index -> Vanagon Share: Facebook Twitter
Reply to topic
Print View
Quick sort: Show newest posts on top | Show oldest posts on top View previous topic :: View next topic  
Author Message
ftp2leta
Samba Member


Joined: October 11, 2004
Posts: 3271
Location: Montreal
ftp2leta is offline 

PostPosted: Sun Mar 27, 2011 6:48 am    Post subject: Vanagon maintenance (1983-2011) Reply with quote

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)

Image may have been reduced in size. Click image to view fullscreen.


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!!!!
Image may have been reduced in size. Click image to view fullscreen.

-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.
Image may have been reduced in size. Click image to view fullscreen.

-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:
Image may have been reduced in size. Click image to view fullscreen.

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:
Image may have been reduced in size. Click image to view fullscreen.


-Replace fuel filter AND pump:
Image may have been reduced in size. Click image to view fullscreen.


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.
------------------------------------------------------
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
Back to top
View user's profile Send private message Send e-mail Visit poster's website Facebook Gallery Classifieds Feedback
candyman
Samba Trout Slayer


Joined: December 20, 2003
Posts: 2694
Location: Missoula MT
candyman is offline 

PostPosted: Sun Mar 27, 2011 7:08 am    Post subject: Reply with quote

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
Back to top
View user's profile Send private message Send e-mail Visit poster's website Gallery Classifieds Feedback
dbean
Samba Member


Joined: July 30, 2010
Posts: 36
Location: Nashville
dbean is offline 

PostPosted: Sun Mar 27, 2011 7:56 am    Post subject: Reply with quote

Thanks, great post! may help me with my coolant issue.
Back to top
View user's profile Send private message Classifieds Feedback
Corwyn Premium Member
Samba Member


Joined: December 29, 2009
Posts: 2225
Location: Olympia, Washington
Corwyn is offline 

PostPosted: Sun Mar 27, 2011 8:28 am    Post subject: Reply with quote

STICKY A great refrence for new owners. I think a TIRE sticky would be good too. I'm full of good ideas . . . Cool
_________________
'90 White Westy ("Knarr")
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 ~
Back to top
View user's profile Send private message Send e-mail Visit poster's website Gallery Classifieds Feedback
eeebee
Samba Member


Joined: July 17, 2009
Posts: 429
Location: Tujunga
eeebee is offline 

PostPosted: Sun Mar 27, 2011 8:36 am    Post subject: Reply with quote

How about cleaning your grounds, replacing the ignition switch, and adding headlight relays.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
carterzest
Samba Member


Joined: January 22, 2008
Posts: 3842
Location: Eagle, ID/Sun Valley, ID
carterzest is offline 

PostPosted: Sun Mar 27, 2011 8:41 am    Post subject: Reply with quote

Nice job Ben and definitely Stickylicious Cool
_________________
Happiness=Portland, Oregon in the rearview mirror!
Back to top
View user's profile Send private message Send e-mail Gallery Classifieds Feedback
Californio
Samba Member


Joined: May 17, 2007
Posts: 1271

Californio is offline 

PostPosted: Sun Mar 27, 2011 10:19 am    Post subject: Reply with quote

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.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
noganav
Samba Member


Joined: January 06, 2006
Posts: 1236
Location: San Diego CA
noganav is offline 

PostPosted: Sun Mar 27, 2011 10:36 am    Post subject: Reply with quote

Excellent information, and a nice summary. Thank you. Applause
_________________
Westfalia Travel Resources Collaborative Map - Please add your favorite places!
http://bit.ly/westymap
Back to top
View user's profile Send private message Visit poster's website Gallery Classifieds Feedback
DAIZEE
Samba Member


Joined: January 26, 2010
Posts: 7552
Location: Greater Toronto Area Ontario West Side
DAIZEE is offline 

PostPosted: Sun Mar 27, 2011 10:49 am    Post subject: Reply with quote

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)
Back to top
View user's profile Send private message Send e-mail Facebook Gallery Classifieds Feedback
edgood1
Samba Member


Joined: September 30, 2004
Posts: 2048
Location: Plymouth, MA
edgood1 is offline 

PostPosted: Sun Mar 27, 2011 11:34 am    Post subject: Reply with quote

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"
Shocked
_________________
1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia
Back to top
View user's profile Send private message AIM Address Gallery Classifieds Feedback
randywebb
Samba Member


Joined: February 15, 2005
Posts: 3815
Location: Greater Metropolitan Nimrod, Orygun
randywebb is offline 

PostPosted: Sun Mar 27, 2011 12:38 pm    Post subject: Reply with quote

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.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
SL1
Samba Member


Joined: December 17, 2010
Posts: 251
Location: Nova Scotia, Canada
SL1 is offline 

PostPosted: Sun Mar 27, 2011 1:01 pm    Post subject: Reply with quote

THANKS BEN

excellent info - as usual
_________________
Steve
1985 GL Westy - 'Bullwinkle'
1978 Super Beetle - 'Rocky'
Back to top
View user's profile Send private message Classifieds Feedback
randywebb
Samba Member


Joined: February 15, 2005
Posts: 3815
Location: Greater Metropolitan Nimrod, Orygun
randywebb is offline 

PostPosted: Sun Mar 27, 2011 2:36 pm    Post subject: Reply with quote

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.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
MakeFast
Samba Member


Joined: January 09, 2011
Posts: 118
Location: Portland, OR
MakeFast is offline 

PostPosted: Sun Mar 27, 2011 2:49 pm    Post subject: Reply with quote

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
Back to top
View user's profile Send private message Classifieds Feedback
Californio
Samba Member


Joined: May 17, 2007
Posts: 1271

Californio is offline 

PostPosted: Sun Mar 27, 2011 3:46 pm    Post subject: Reply with quote

Agree with the three levels of importance.

Very useful thread.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
PNWesty
Samba Member


Joined: October 18, 2010
Posts: 138
Location: Seattle
PNWesty is offline 

PostPosted: Sun Mar 27, 2011 3:57 pm    Post subject: Reply with quote

Thanks for the info. Brake line replace added to top of Spring To Do list.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
UNIBLONDER
Samba Member


Joined: March 25, 2011
Posts: 15
Location: Southeast USA
UNIBLONDER is offline 

PostPosted: Sun Mar 27, 2011 3:58 pm    Post subject: Reply with quote

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.
Back to top
View user's profile Send private message Classifieds Feedback
ftp2leta
Samba Member


Joined: October 11, 2004
Posts: 3271
Location: Montreal
ftp2leta is offline 

PostPosted: Sun Mar 27, 2011 4:13 pm    Post subject: Reply with quote

edgood1 wrote:


now we just need to post a parts list and price for "all of the above"
Shocked


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
Back to top
View user's profile Send private message Send e-mail Visit poster's website Facebook Gallery Classifieds Feedback
bjrogers86auto
Samba Member


Joined: March 26, 2009
Posts: 1375
Location: Halifax, N.S.
bjrogers86auto is offline 

PostPosted: Sun Mar 27, 2011 5:04 pm    Post subject: Work Reply with quote

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.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
ftp2leta
Samba Member


Joined: October 11, 2004
Posts: 3271
Location: Montreal
ftp2leta is offline 

PostPosted: Sun Mar 27, 2011 5:34 pm    Post subject: Re: Work Reply with quote

bjrogers86auto wrote:
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


Smile

I miss NS... such a nice place.
_________________
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
Back to top
View user's profile Send private message Send e-mail Visit poster's website Facebook Gallery Classifieds Feedback
Display posts from previous:   
Reply to topic    Forum Index -> Vanagon All times are Mountain Standard Time/Pacific Daylight Savings Time
Page: 1, 2, 3, 4  Next
Page 1 of 4

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum

About | Help! | Advertise | Donate | Premium Membership | Privacy/Terms of Use | Contact Us | Site Map
Copyright © 1996-2023, Everett Barnes. All Rights Reserved.
Not affiliated with or sponsored by Volkswagen of America | Forum powered by phpBB
Links to eBay or other vendor sites may be affiliate links where the site receives compensation.