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10degnorth Samba Member

Joined: March 07, 2018 Posts: 480 Location: Bend, Oregon
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Posted: Tue Oct 02, 2018 9:34 pm Post subject: A Vanagon, a Highschooler, and a Passion |
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This thread was formerly “A Wolfsburg, Two Engines, and a Highschooler”, however it seems to have outgrown that name as I only have one engine. This thread details the build of my 1988 Wolfsburg Vanagon powered by a 2.1 WBXer. So far the entirety of the build has been carried out through me being in highschool. Enjoy
Hey, I thought it would be neat to start telling the story of my 1988 Wolfsburg, so here ya go:
After a nearly successful attempt to convince me to give up on my Vanagon dreams by my uncle, who is himself a vanagon owner, I bought my burgundy 1988 Wolfsburg Weekender in late March 2018 for $1200 (everything I had at the time).... with a blown engine.
I worked all summer to build up a sizable budget to be able to get to get it running. I compared the pros and cons of different engine configurations, including Subarus, m-TDI's, etc... And in the end decided that the easiest and most economic in the short term would be a WBXer. So my hunt began, I purchased a "new" engine off craigslist from a reputable local Vanagon mechanic (Karl out in lapine) for $500. But this engine had a catch... An engine bay fire (most likely caused by old and cracked fuel lines) had melted all the rubber and plastic on the passenger side and a sizable amount on the drivers side. But it had great compression, something my original engine was lacking.
Over the course of the summer I began clean up the new engine and strip it down to the bare minimum and take inventory while assembling my list of new parts. Once I had a sizable list of necessary parts I began ordering. I got all new engine compartment coolant lines and the stainless kit for the long lines. I bought new fuel lines and new a new water pump. Anything that couldn't be salvaged from one of the two engine, the original or the engine fired one was bought new.
Over the past 2-3 months I have begun assembling the final engine that will hopefully power my Wolfsburg. I am nearing the end of the mechanical stages of the build. New fuel lines finally went on this afternoon, along with the distributor. The purple tint has since been removed, along with the original engine, the pics are from when I first picked it up.
If you have and comments or questions I would love to hear them.
Last edited by 10degnorth on Thu Dec 06, 2018 11:34 am; edited 2 times in total |
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sanchius  Samba Member

Joined: May 03, 2007 Posts: 1528 Location: IN
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dabaron Samba Member

Joined: June 21, 2018 Posts: 2676 Location: Philly, mang
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Posted: Wed Oct 03, 2018 4:54 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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Very nice score... Looking forward to the future posts of the engine in and you parked in front of Smith Rock
and bravo for taking on the challenge of an engine swap. i would never have tried anything like that when i was in high school. _________________ 1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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calo1956 Samba Member

Joined: April 18, 2011 Posts: 712 Location: long Island new york
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Posted: Wed Oct 03, 2018 6:11 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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Cool build, I admire your dream and passion! Don't ever let anyone shatter your dreams!Thats such a cool vehicle for someone your age. I bet none of the other kids at school will be driving around in anything that cool. i think it will be a chick magnet! Theres not a day that goes by that someone doesn't stop to ask about my Westy! _________________ Enjoy the ride....
72 bug
80 westfalia |
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CurtisS Samba Member

Joined: March 01, 2006 Posts: 128 Location: Kingston, WA USA
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Posted: Wed Oct 03, 2018 6:22 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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Thanks for sharing your story and i look forward to reading more (with pics! ).
Check the Samba Classifieds as well for parts such as that fiberglass skirt piece to the left of the slider.
Cheers! _________________ If "con" is the opposite of "pro", what is the opposite of "progress"? |
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markswagen Samba Member
Joined: January 28, 2018 Posts: 1389 Location: san diego
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Posted: Wed Oct 03, 2018 6:44 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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Pay close attention to the rubber head gaskets, I have seen a repaired and re used fire damaged engine, it leaked coolant through the top where the seals had melted, if your look OK then likely they are, this one the seals had clearly suffered, the owner had kept the engine running for years afterwards, knowing he had to add coolant once a week, more if he drove longer distances.
Good luck with your van, and kept the pictures coming. _________________ markswagen {mobile mechanic} san diego area all early VW's cared for.
619 201 0310
ISO vw tool 3159 |
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markswagen Samba Member
Joined: January 28, 2018 Posts: 1389 Location: san diego
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Posted: Wed Oct 03, 2018 6:50 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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Noticing that you have an auto, please do a transmission cooler swap, take the water to ATF cooler out, and fit an air to AFT cooler.
My vote on that matter would be to use the small car performance cooler, I am going to be fitting one to a customer's vanagon, today.
You do not want other have to deal with a transmission full of coolant, and cooling system with ATF in it, I have, on my wife's carat, not something I want other have to go through again.
https://smallcar.com/vanagon/transmission-cooler-kit.html _________________ markswagen {mobile mechanic} san diego area all early VW's cared for.
619 201 0310
ISO vw tool 3159 |
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dabaron Samba Member

Joined: June 21, 2018 Posts: 2676 Location: Philly, mang
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Posted: Wed Oct 03, 2018 7:04 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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markswagen wrote: |
Noticing that you have an auto, please do a transmission cooler swap, take the water to ATF cooler out, and fit an air to AFT cooler.
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how prevalent is the ATF cooler failure? _________________ 1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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bokonon42 Samba Member

Joined: December 20, 2016 Posts: 106 Location: Bay Area, CA
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jimf909 Samba Member

Joined: April 03, 2014 Posts: 7970 Location: WA/ID
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Posted: Wed Oct 03, 2018 7:35 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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Well done. Vanagon owners always seem to try to talk others out of buying a Vanagon.
It looks like you've got a nice van to work on.
Looking forward to seeing the build! _________________ - 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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borninabus  Samba R&D Dept.

Joined: May 18, 2006 Posts: 4669 Location: Arizona Highways
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Posted: Wed Oct 03, 2018 7:39 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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dabaron wrote: |
markswagen wrote: |
Noticing that you have an auto, please do a transmission cooler swap, take the water to ATF cooler out, and fit an air to AFT cooler.
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how prevalent is the ATF cooler failure? |
not very.
nice van  _________________ 88 Van WBX, A/T - 13 JSW TDI 6M/T - 2012 Touareg TDI Sport |
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dabaron Samba Member

Joined: June 21, 2018 Posts: 2676 Location: Philly, mang
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Posted: Wed Oct 03, 2018 8:05 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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jimf909 wrote: |
Well done. Vanagon owners always seem to try to talk others out of buying a Vanagon.
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i think we are trying to spare others from the misery of ownership
my 3k Vanagon is now up to 5k. wheels and sound systems ain't free! _________________ 1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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IdahoDoug Samba Member

Joined: June 12, 2010 Posts: 10350 Location: N. Idaho
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Posted: Wed Oct 03, 2018 9:27 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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Nice van, well done. I get to Bend once a year or so, so if you find you are needing some esoteric part let me know and I may have room to bring it.
On the trans cooler - is there an easy way to bypass it by blocking coolant lines that does not create a circulation issue for the engine coolant? I live in a cooler northern climate and when I'm climbing passes I hold the auto trans in the right gear, put the flashers on and mosey up without a lot of drama.
Doug _________________ 1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader |
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T3 Pilot Samba Member

Joined: January 10, 2011 Posts: 1508 Location: Deep South of the Great White North
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SCM Samba Member

Joined: January 26, 2011 Posts: 3280 Location: Bozeman MT
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Posted: Wed Oct 03, 2018 9:47 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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borninabus wrote: |
not very. |
But it's catastrophic if it does happen.
The OEM cooler is no longer available IFAIK so if you ever even want to replace it you'll end up with one of the safer aftermarket ones anyway. If you've already go the van torn apart it may be wise to do the swap now.
I agree - nice van! _________________ '91 Westfalia GL Automatic (GTA "Turbo" Rebuild w/Peloquin) and 2.3L GoWesty Engine |
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dabaron Samba Member

Joined: June 21, 2018 Posts: 2676 Location: Philly, mang
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Posted: Wed Oct 03, 2018 10:04 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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SCM wrote: |
borninabus wrote: |
not very. |
But it's catastrophic if it does happen.
The OEM cooler is no longer available IFAIK so if you ever even want to replace it you'll end up with one of the safer aftermarket ones anyway. If you've already go the van torn apart it may be wise to do the swap now.
I agree - nice van! |
can i borrow $170.00 _________________ 1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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shagginwagon83  Samba Member

Joined: February 07, 2016 Posts: 4183 Location: SWVA
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Posted: Wed Oct 03, 2018 10:14 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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I went to high school in a retirement town. A lot of $$$ in that town. There was a couple of kids with brand new Jeeps, FJ Cruisers. Really dumb to give a new driver a new car - but anyway - if there was a vanagon in that parking lot - def. would be the coolest. Good luck. I hope you make those new Jeep kids jealous  _________________ Making the world a better place.
Brandon
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram: @joannthevan |
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Gnarlodious  Samba Member

Joined: September 28, 2013 Posts: 2374 Location: Adobe Jungle USA
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Posted: Wed Oct 03, 2018 10:37 am Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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Super nifty van!
dabaron wrote: |
we are trying to spare others from the misery of ownership |
More likely we are spreading disinformation to keep the prices low! _________________ Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit |
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dobryan Samba Member

Joined: March 24, 2006 Posts: 16858 Location: Brookeville, MD
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markswagen Samba Member
Joined: January 28, 2018 Posts: 1389 Location: san diego
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Posted: Wed Oct 03, 2018 1:05 pm Post subject: Re: A Wolfsburg, Two Engines, and a Highschooler |
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i guess it depends on who you talk to, i have had to clean two cooling systems, and replace automatic transmissions due to the cooler failing, as far as i see, they are a time bomb, you are right, they may never go off, i know personally of 2 that have, one i got paid to fix, the other, my wifes, i did not, i really hope i never have to do it again, for the cost of the cooler, and a couple of hours, it makes sense, to me at least, the van i went out to do this morning, when i got under there, there was no clean and clear space to mount the cooler where i would be happy with it, due to the added stuff adventure wagens, and a mess AC line install, there is enough space for the go westy transmission cooler, so the customer has decided to go that route instead.
back to flushing out the cooling system, it took a couple of gallons of dishwasher detergent, and about 100 gallons of water, to get it clean, 5 full flushes, all the mixed coolant aft was caught in big concrete mixing trays, and take to the recycling center in 5 gallon buckets, that was 2 full weekends, then was the replacement transmission $1250 for a rebuild, my labor on top of that, would not see a lot less than $2700, my customers, he did a lot of the flushing, i got the worst of it, and he finished up, transmission cast was the same.
it's not a fun job to have to deal with.
borninabus wrote: |
dabaron wrote: |
markswagen wrote: |
Noticing that you have an auto, please do a transmission cooler swap, take the water to ATF cooler out, and fit an air to AFT cooler.
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how prevalent is the ATF cooler failure? |
not very.
nice van  |
[/s] _________________ markswagen {mobile mechanic} san diego area all early VW's cared for.
619 201 0310
ISO vw tool 3159 |
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