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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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 Posted: Wed Jan 23, 2019 6:37 pm Post subject: Re: Building a bus for travel in Europe |
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Using the lift for multi-tasking.
Swapping engines from one platform to another.
Off with the old.
Removing the new from the carrier from shipping and then setting onto the ATV lift.
Clutch and pressure plate installed, ready to mate with transmission.
Successful mating. Ready to install.
(Likely next week. We visit relatives in RI this weekend.)
_________________
Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD
"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson
MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646
Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371
The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794 |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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| Posted: Mon Jan 28, 2019 2:33 pm Post subject: Re: Building a bus for travel in Europe |
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Spent some time prepping to install the engine/trans into the bus.
Lots of work installing coolant hoses and H stainless Steel manifold, and cleaning LOTS of dust, dirt, sand from the tops of every surface in the rear suspension. This bus was taken off pavement frequently by the looks of it. (No pics of the dirt though.)
This is why you need to redo the main ground from the trans to the body. The spot where the ground was bolted to the body had rusty threads and paint on the frame member. It likely was somewhat ground challenged. I scraped away the paint (final result was better than that interim pic) and added a dab of dielectric grease for the new ground cable. (The black was overspray from me, but look at the layer of white that was underneath.
Ready to go.
In position. Notice that it is solidly on the ATV jack. NO other support needed. It really is firmly on there.
After lowering the body down onto the engine/trans I put the trans mount bolt thru and then lowered some more until the carrier bar ends were flush to the side frame member and installed the bolts. Canting the engine/trans up in the front on the jack allows this to go easily. It is bolted up.
Now I get to hook up all the fiddly bits.... 
_________________
Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD
"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson
MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646
Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371
The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794 |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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| Posted: Mon Feb 11, 2019 3:33 pm Post subject: Re: Building a bus for travel in Europe |
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A few months before I took the bus off the road to do this work the idle went wonky. It got to where in just a day it would rev up to 3-4000 rpm and even accelerate on the road... not good. After the mind of it's own reving I pulled the plug from the ICV and the idle went back to normal. As part of gathering parts for the rebuild I scored a nice used ICV and ICU. Not sure which of the original parts was bad until today when I replaced the ICU.
When I pulled the ICU from the D pillar there was water dripping out of it.... look at bottom corner....
I think I know which component went bad. 
Replacement used ICU in front of original ICU.
_________________
Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD
"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson
MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646
Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371
The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794 |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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danfromsyr
Samba Member
Joined: March 01, 2004
Posts: 15144
Location: Syracuse, NY
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| Posted: Thu Feb 14, 2019 1:06 pm Post subject: Re: Building a bus for travel in Europe |
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I move the ICU to inside the air filter.
protected from engine heat, and well protected from water..
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| Abscate wrote: |
| These are the reasons we have words like “wanker” |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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kevinj73us
Samba Member
Joined: September 25, 2011
Posts: 228
Location: Laurel, MD
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| Posted: Fri Mar 15, 2019 1:54 pm Post subject: Re: Building a bus for travel in Europe |
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I have something for your build that I'll bring over tomorrow. We can also discuss any custom vinyl you need. 
kj
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1973 Station Wagon
m-plate |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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tristessa
Samba Member
Joined: April 07, 2004
Posts: 3992
Location: Portland, OR
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| Posted: Fri Mar 15, 2019 5:11 pm Post subject: Re: Building a bus for travel in Europe |
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| dobryan wrote: |
| Why am I slightly scared... |
Eh, it's just custom vinyl he's talking about. If it was custom latex or leather, THEN I'd be scared. |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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| Posted: Sat Mar 23, 2019 1:54 pm Post subject: Re: Building a bus for travel in Europe |
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Totally removed the A/C (sorry Zeitgeist).
God what a chore this is. The wiring from the rear to the front is not trivial to remove. I've likely got 98% of a complete A/C system for someone (will list it in the classifieds).
But now I have a huge amount of room for storage on the D pillar and head banger area.
A/C can only really be used while driving and I need storage while camping which is 90% of the use of this bus... so off it goes.
_________________
Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD
"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson
MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646
Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371
The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794 |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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| Posted: Sat Mar 23, 2019 2:13 pm Post subject: Re: Building a bus for travel in Europe |
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Besides removing the A/C and doing details in the engine bay I had procrastinated on starting the new engine. Didn't want to F anything up.
So for a couple of weeks I gathered supplies and courage and then went thru Rocky Jennings break in procedure.
Rocky has a 20 minute cam break in procedure that is done in 4 five minute segments. The engine started fine and I started thru the first 5 minute cycle. At the 3-4 minute time the engine started running rich but I could keep it at the right rpms. Not enough time to diagnose then. Same issue for the next three cycles. Got the timing dialed in though (I had not removed the distributor mount bracket from the distributor so I could install the distributor on the new engine at the exact same timing it was on the previous one).
Based on what I had read on the samba I suspected Temp2 or O2 since they come on line about then. (I haven't run a wbx for 14 years, only the Subie EJ25)
I took it out for a drive to do the routine seat the rings. Still had rich running after it went closed loop but I could get by if I turned off then on to recycle the ECU. Was a pain also because I only had R, 1, 3....  Two things to fix.
At home I downloaded the Protraining manual and started going thru the tests. Temp2 tested fine on resistance vs temp. O2 gave funky readings when the connector was grounded. (Dan Beatty helped me out here). I slept on it a few days and then realized that I had been using dielectric grease on all the engine compartment connectors. But.... since it is conductive perhaps it was bridging the O2 sensor connector contacts and giving spurious readings. The O2 only fluctuates a few tenths of a volt so it is sensitive to this.
Edit: dielectric grease is apparently not conductive so my theory is not correct. But the results are good so maybe the electronic cleaner helped.
So yesterday I doused the connectors with electronic connector cleaner and let it dry over night. Today I ran the Protraining tests and they looked good. Started it up and after 7 minutes of idling all was fine. Tomorrow I'll go for another test drive.
And of course my shifting difficulty was the usual mounting the shift plate on the trans to the rear vs the front...
All seems to be going well.
_________________
Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD
"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson
MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646
Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371
The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794 |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16505
Location: Brookeville, MD
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jimf909 
Samba Member
Joined: April 03, 2014
Posts: 7474
Location: WA/ID
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| Posted: Sun Mar 24, 2019 11:38 am Post subject: Re: Building a bus for travel in Europe |
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I love this thread. Thanks for all the great info.
I'm sure you've thought of this but the high-top may make work on the lift less awesome due tot being able to lift the van as high. I hadn't considered this until I was hunched over under the van while it was on my mechanic's lift.
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- Jim
| Abscate wrote: |
Do not get killed, do not kill others.
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Current: 1990 Westy Camper - Bostig RG4, 2wd, manual trans w/Peloquin, NAHT high-top, 280 ah LFP battery, 160 watts solar, Flash Silver, seam rust, bondo, etc., etc.
Past: 1985 Westy Camper - 1.9 wbx, 2wd, manual trans, Merian Brown, (sold after 17 years to Northwesty who converted it to a Syncro). |
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Alaskaberrys
Samba Member
Joined: June 19, 2016
Posts: 1001
Location: SE Alaska
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| Posted: Sun Mar 24, 2019 12:10 pm Post subject: Re: Building a bus for travel in Europe |
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Ditto, love this thread!
And really appreciate the effort to describe the progress and sharing the costs is great - thanks for that. A real eye opener to anyone scratching their head why a 30 year old vehicle might cost more then $150
Curious if your deducting from the total when anything sells?
_________________
'91 Westfalia, Bordeaux Red Pearl 2.1L 2wd Auto
'91 T3 Syncro Doka, Escorial Green 1.9L TD AAZ “Gremian” (to provoke, irritate, exasperate, vex...) |
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