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Microbusdeluxe 
Samba Member
Joined: July 26, 2003
Posts: 980
Location: Bellingham, WA
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 Posted: Sat Apr 05, 2014 12:41 pm Post subject: Exhaust leak at heater box |
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I have an '81, aircooled California emissions vanagon. Since the air-cooled experts tend to hang on this forum &, as I understand it, the later bays have the same 2000cc fuel injected engines, I'm venturing into this new territory to ask my question.
I was told that I have an exhaust leak in the right hand heater box. I do NOT smell any exhaust in the heat system, which makes me wonder if there is indeed a leak within the box. Before I tear apart things (and break off studs!) I'd like to know of anyone's experience of detecting leaks.
Second question. If replacement is on my horizon and since the Cali system exhaust is unobtanium, can anyone recommend an aftermarket set-up that might even give me a bit more oomph and not be loud?
Thanks in advance for all of your help.
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Waves2day
Samba Member
Joined: October 15, 2008
Posts: 408
Location: Bay Area, CA
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| Posted: Sat Apr 05, 2014 3:26 pm Post subject: |
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Are you talking about the manifold to the head leaking? Or are you talking about muffler leaks? I only ask cause I don't think heaterboxes are different regarding cali or federal...
Can you hear a leak(ticking sound) while its running?
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Sam
1976 Westfalia Camper Pop-top
1972 Westfalia Hardtop (sold) |
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busdaddy
Samba Member
Joined: February 12, 2004
Posts: 51153
Location: Surrey B.C. Canada, but thinking of Ukraine
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| Posted: Sat Apr 05, 2014 3:34 pm Post subject: |
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Park the bus (or Van in your case) with one wheel up on a curb and set the brake, then have a helper hold a towel or thier foot against the end of the tailpipe while you lay underneath and listen for where the sound is coming from. Watch out, those pipes under there are hot!
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Microbusdeluxe
Samba Member
Joined: July 26, 2003
Posts: 980
Location: Bellingham, WA
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| Posted: Sun Apr 06, 2014 5:10 pm Post subject: |
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The leak appears around the heat exchanger. My question is if the leak is indeed in the exhaust pipe which is surrounded by the heat exchanger would one smell exhaust in the cabin when the heat vents are open? If not, then I'm guessing the leak is coming from the connection to the head, but it's real hard to tell, even with "the ol' plug the exhaust & feel around trick". I know there is a leak in the special only-on-a-Cali-stainless steel header on the left side. I am assuming that there is a 50/50 chance of breaking off a stud when trying to remove the pipe, so I'm feeling lots of trepidation for the job.
The Cali emissions definitely has a unique heat exchanger on the left side (see Bentley manual for picture).
Thanks for your advice.
_________________
'69 Squareback RIP
'65 21 window deluxe sold before the price spike, damn it.
'70 rhd bay now a taxi in South Sudan
'81 Westy sold
'89 hightop Westy Joker syncro 16" now with Bostig! |
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Waves2day
Samba Member
Joined: October 15, 2008
Posts: 408
Location: Bay Area, CA
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| Posted: Sun Apr 06, 2014 5:29 pm Post subject: |
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Sorry for the misread. Didn't know the HE was different on the cali model sorry. I would assume you could smell it but maybe not... anything is possible. Sorry again for being of no help. Good luck.
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Sam
1976 Westfalia Camper Pop-top
1972 Westfalia Hardtop (sold) |
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aerosurfer
Samba Member
Joined: March 25, 2012
Posts: 1602
Location: Indianapolis, IN
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| Posted: Sun Apr 06, 2014 5:58 pm Post subject: |
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So then the question, becomes do you need (and want) to keep the Cali style HE? If so then you have some big work to do, but if you are able to be flexible can you simply acquire a non-cali exhaust setup and move-on? Either way sound like you need to take care in removing the exhaust stud
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77 Westy 2.0L Rockin and Rolling Resto!
72 Sportsmobile (sold)
79 Tran$porter... Parts car money machine (gone) |
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old DKP driver
Samba Member
Joined: March 30, 2005
Posts: 4145
Location: Los Gatos,Ca.
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| Posted: Sun Apr 06, 2014 7:02 pm Post subject: Ca heat exchanger |
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Take your time and use a good penetrant like PB-blaster, Kroil, or liquid wrench.
You can't force these exhaust nuts off or YOU will break the studs.
Spaying 2 or 3 times a day for a few days will most likely be enough
and then, you will need to take your time loosening any of the nuts.
As for the CA. system yes, it is an abomination for an exhaust system but,
the design worked for VW in order to pass the emission law for CA.
Take your time doing this Please. 
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