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A 1991 Syncro L Single knob “Rome” rebuild
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Ceckert64
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PostPosted: Sun Dec 29, 2024 8:30 pm    Post subject: A 1991 Syncro L Single knob “Rome” rebuild Reply with quote

Hello all, I figured I’d give a little introduction,

I’ve been an aircooled owner for a long time and been into the bays but I decided it was time to get something a little newer. My current daily is my 71 westy I dragged out of a junkyard last year and subie swapped, it’s been great but I’ve always wanted 4wd since I like to do a bit of off-roading and go to school in a very steep, snowy town of Houghton. I sold my 72 westy I restored in high school recently and was thinking about another project. I was between a diesel rabbit truck and a Syncro.

A while ago (maybe year) I saw two syncros projects for sale in Minnesota that were for sale on here that were clean, but I still had the 72 and higher than I was looking to drop. The ads went down, I forgot about them then the ad came up again recently for the 87 (currently still for sale). I talked with the owner, and he said he had a 91 he’d sell for not much more and was cleaner, I got the pictures from him and it was extremely clean.

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It was a Minnesota van that he bought with the 87 from the original owner. The previous owner bought it new on a trip to New Mexico and drove it back. He used it for ski trips out west and took car of it well. It had 170k miles but minimal rust and very few dents. It was parked in 05 and was inside/ on gravel outside for a long time.

After much think and debating, I decided I wanted to get it. I got my dad to come with me to pick up with me (big thanks to him). We visited family in Indiana over the last few days and then hit the road early this morning to pick it up in Minnesota. We got it, the seller is a great guy and helped get it on the trailer and he had a lot of cool VWs, he still has an 87 Syncro for sale too.
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It’s in amazing condition to say the least, the interior is perfect, it’s very complete. I only found one rust hole and the cat was cut off. It even had the original rear bumper and hubcaps. It also came with dealership receipts of work done. I found it had 7K in work done on it between 2002-2005 Shocked I believe it got a new engine in 02 even from the one receipt, it seems like it was well taken care of compared to my last projects.

This seems like it should be an easy project compared to my previous, it wasn’t full of rotting things or driven into the ground. It was made more recently than my previous projects had been on the road Laughing To say the least I’m excited and lucked out to find this one and be able to get it.

More pictures and details to come. I’m passenger as my dad is still driving across Wisconsin right now. I’ll start on it tomorrow once I get back home later in the day with it.

I’ll probably need some help with a few things since I’ve barely touched a vanagon before. I helped my friend with his 87 Wolfsburg edition a little and got the chance to drive that. That’s a bit what pushed me to get one and seeing vanagons at the campouts I went to over the summer in my 71. And my 71 is what convinced my friend to get the 87 going to it’s a dangerous cycle Laughing

Thanks for reading, Aiden
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Last edited by Ceckert64 on Sat Jan 04, 2025 2:52 pm; edited 1 time in total
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syncrodoka
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PostPosted: Sun Dec 29, 2024 9:52 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Nice score! Have fun
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PostPosted: Sun Dec 29, 2024 11:02 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Cool project.
And air conditioning!
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PostPosted: Mon Dec 30, 2024 12:35 am    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Commonly referred to as an "L" model. Most of them were bought by converters to do Pop and High top conversions. Since they were bare bones and cheaper then a Carat or standard passenger van and most came with AC.

Nice find, I've owned a couple of them in 2Wd and have a soft spot for them.

Stacy
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PostPosted: Mon Dec 30, 2024 8:59 am    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Welcome to the madness. Cool Laughing
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PostPosted: Mon Dec 30, 2024 9:08 am    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

You'll be planning a trip to Syncro Solstice soon.....
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PostPosted: Mon Dec 30, 2024 9:30 am    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Ceckert64 wrote:


This seems like it should be an easy project compared to my previous


Famous last words Very Happy

Welcome and congratulations! I love the Graz vans. Can't wait to see it back on the road!
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Ceckert64
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PostPosted: Mon Dec 30, 2024 1:28 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

syncrodoka wrote:
Nice score! Have fun

Thanks! I’m excited for the project! It’ll be fun to off-road
Sodo wrote:
Cool project.
And air conditioning!

Thank you! It seems to have most of the parts, it’s missing the overhead ducts. I will be curious if it still works or not.
16CVs wrote:
Commonly referred to as an "L" model. Most of them were bought by converters to do Pop and High top conversions. Since they were bare bones and cheaper then a Carat or standard passenger van and most came with AC.

Nice find, I've owned a couple of them in 2Wd and have a soft spot for them.

Stacy

Good to know! I like the interior layout, though I am a sucker for a westy interior and camper setup. I will probably add a table inside. I don’t mind the bare bones since there is less to go wrong with stuff like power windows and other features. Thanks for the info Stacy!
dobryan wrote:
Welcome to the madness. Cool Laughing

I’m excited to learn more about vanagons, I’ve learned a lot about the aircooleds but not any water cooled VW’s.
mtnhome wrote:
You'll be planning a trip to Syncro Solstice soon.....

That would be a cool event to make!
joetiger wrote:
Ceckert64 wrote:


This seems like it should be an easy project compared to my previous


Famous last words Very Happy

Welcome and congratulations! I love the Graz vans. Can't wait to see it back on the road!

If it is my famous last word I’m scared Laughing last project was my 71 which I had to replace half of the frame rails, inner, middle and outer rockers on both sides, floors, many metal patches, replace every brake part, rebuild an engine for it then Subaru swap it and etc. So…. Hopefully it’s not more work than that Laughing

Thank you, hopefully I can get it running in the next few days. I will completely go through it though after I get it to run a little bit at least and see what it needs. I will replace all fuel lines, upgrade plastic bits, etc to improve reliability and prevent fires.

I’m still on the way back with it, only a few hours left till it’s back.

After some more looking at receipts, I figured out it did get a new long block in 2002 at 147k miles due to internal engine damage, one could assume the rod bolt let go.

So the first question, would a 2.1L replacement long block from 2002 have the problematic connecting rod bolts that fatigue and fail or would it have been updated and fixed?

Here are some underside shots at the gas station and the manuals/ receipts that came with it. The PO unhooked the driveshaft on it to tow dolly it.
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Xevin Premium Member
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PostPosted: Mon Dec 30, 2024 5:23 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Cool
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PostPosted: Tue Dec 31, 2024 11:21 am    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

As others have opined, “easy” and “project” are two words we never use together here on Samba. Vehicles that are stored long periods of time always have issues from non-operation. Start “easy” with a wash job, fresh fuel, fluid changes, and a tune-up to see if it runs. Then new tires and new fuel lines. That said, sounds like it’s not your first rodeo. Good luck!
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PostPosted: Tue Dec 31, 2024 3:02 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Actually, a long block replacement at 147K miles sounds about right for a tired WBX engine. “Internal damage” could have been almost anything. May also have been speedier repair than rebuilding the original motor. Wouldn’t worry about piston rod bolts right now. Others may differ.
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PostPosted: Tue Dec 31, 2024 9:37 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Red Ryder wrote:
As others have opined, “easy” and “project” are two words we never use together here on Samba. Vehicles that are stored long periods of time always have issues from non-operation. Start “easy” with a wash job, fresh fuel, fluid changes, and a tune-up to see if it runs. Then new tires and new fuel lines. That said, sounds like it’s not your first rodeo. Good luck!

Compared to what I’ve done in the past this is easy at least Laughing half to three quarters of the work of the rest of my projects have been body work and rust repair which this needs neither besides a few small spots. And the mechanicals seem much better than my previous too. I’ve got that as my plan going forward.

Red Ryder wrote:
Actually, a long block replacement at 147K miles sounds about right for a tired WBX engine. “Internal damage” could have been almost anything. May also have been speedier repair than rebuilding the original motor. Wouldn’t worry about piston rod bolts right now. Others may differ.

I figure if it’s a replacement, I should be good for 70k miles before I have to worry about rod bolts, they seem to fail at 100k at the earliest. It seems like the engine should be good.

On the way home yesterday, I stopped and power washed it on the way home, it cleaned up nice. When I got home, I started and threw out the home carpeting that was put in it. It was covered in mouse crap and poison. Then I went through the interior vacuuming it, then taking a wet soapy rag and wiping down everything in the interior that wasn’t cloth. It cleaned up really nice and is all in good shape. There is one small section where the stitching came undone on the passenger seat but otherwise it’s perfect. The floors are solid and zero rust.
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The engine got a quick wash when I washed the rest of it. It’s all there. I pulled plugs and turned it over today and inspected it with a scope. It turns over nice and smooth. Tomorrow I plan on trying to get it going. I had to do some work on my 71 before I could spend too much time on this.
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The worst thing I’ve found for body damage is someone hooked to the front edge of the frame rails by the bumper and tore the metal. Not too badly though, I’ll just clean it up and re-weld it.
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I put the rear carpet and mattress on the roof while I worked on the engine
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I also pulled down the spare tire, there were climbing ropes in a bag in it Laughing
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I also found this in a plastic bag twist tied to the heater lines, it looks like it’s used for filing up coolant Question anyone that can confirm or knows?
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Is this just a test plug?
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I also hooked up a battery to test the electrical, most everything worked! The turn signals and hazards work, wipers, squirters, dome lights, driving lights, high beams, dash lights, rear heater fan, horn, AC fan, radio, side markers after giving them a tap, brake lights, starter and a few other things I’m forgetting.

What didn’t work was the low beams, they came on with the brights but when I hit low beams, all the lights went out. The front heater fan didn’t work. The reverse lights didn’t work either. I was happily surprised. There was only one burnt out bulb.
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Red Ryder
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PostPosted: Wed Jan 01, 2025 11:14 am    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Great progress! No low beam headlights might be just bad bulbs as these are two-filament bulbs. Check the fuse block for this circuit as well.
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PostPosted: Wed Jan 01, 2025 12:49 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

in a post on ere maybe 2-3 days ago someone was removeing complate A/C system (everything) even ad tunnels for your that seem missing. he was oin offer them to some that need them.

I can't recall user name...
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PostPosted: Wed Jan 01, 2025 12:54 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

found it. it was

https://www.thesamba.com/vw/forum/viewtopic.php?t=798717

loro17 screen name
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PostPosted: Wed Jan 01, 2025 5:55 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Wow that looks like a great find. You've even got the apparently rare rubber floor mats. I didn't realize they were backed with sound deadening. I wish I could find a set!

I wouldn't be surprised if your AC even works.
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PostPosted: Thu Jan 02, 2025 12:22 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

If you haven't already, check out this thread, an extremely thorough and well-documented Syncro full rebuild.

The photos have been a great resource for me on simply figuring out how the van fits together.

https://www.thesamba.com/vw/forum/viewtopic.php?t=592734
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'91 Wolfsburg Carat "Barchetta"

"get metaphysical with it. if it's simply a means to get to and from places, it will let you down. if it becomes your zen, it can't fail you." -dabaron

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Ceckert64
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PostPosted: Thu Jan 02, 2025 10:10 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Red Ryder wrote:
Great progress! No low beam headlights might be just bad bulbs as these are two-filament bulbs. Check the fuse block for this circuit as well.


I’ll have to check out the bulbs and fuses tomorrow, thanks for the tip!

mike boland wrote:
in a post on ere maybe 2-3 days ago someone was removeing complate A/C system (everything) even ad tunnels for your that seem missing. he was oin offer them to some that need them.

I can't recall user name...

Thank for the link! I might reach out to him About the A/C parts, it’d be cool to have it all there. It odd they were taken out along with the vents in the front section.

4Gears4Tires wrote:
Wow that looks like a great find. You've even got the apparently rare rubber floor mats. I didn't realize they were backed with sound deadening. I wish I could find a set!

I wouldn't be surprised if your AC even works.

Thank you! I didn’t realize they are rare, I like them way better than carpet. They only have those two long blocks under them, no other backing.

It’d be nice if it does work! There is a sticker on the air filter housing saying R134a retrofit, would it have been R12 originally? It looks like the A/C system has been opened up before.

joetiger wrote:
If you haven't already, check out this thread, an extremely thorough and well-documented Syncro full rebuild.

The photos have been a great resource for me on simply figuring out how the van fits together.

https://www.thesamba.com/vw/forum/viewtopic.php?t=592734

I’ll have to give that a look, thanks for the link! I always like looking through a good build thread. I was reading through your Carat thread the other day, it’s looking good!

Yesterday I got the oil changed and a new filter on. The filter refused to come off, the old o-ring glued itself in place. The oil filter looked like it went through war by the time I got it off Laughing

After that, I drained the fuel tank. It was pretty varnished at the bottom and nasty. Thankfully only two gallons of gas were in it. The fuel pump was varnished solid and the supply end rotted off inside the supply hose from the tank. But when I pulled the pressure side, it was still pressurized and the fuel was clean thankfully. I had a new spare pump for a baywindow that was an exact replacement. I put that in and put fresh gas in it and decided to give it a try.

With some starting fluid, it started up and ran smooth on starting fluid but quickly died. After another couple trys with starting fluid, it would run but sounded like not all cylinders were firing. I pulled the injectors and only one was firing Shocked that might do it. So I pulled the injectors planning on taking them to get rebuilt today at a shop my friend had his done at.

I figured I might as well replace the fuel lines. I had a roll of gates barricade fuel injection line I had bought for my 72 a year or two back. I went through and worked on replacing all of the fuel lines yesterday and earlier today. I re-used the old vinyl sheath and cut the new lines to the length of the original. I will say the supply and return lines over the tank were a pain. I figured out the best way to pull the lines are attach the new line to the end of the old line in the wheel well. I cut the old end of the fuel line off where it was expanded for the fitting and used the Syncro fuel line barb used for pulling the engine and stuck that into the new and old line to hold them together to pull through. I then duct-taped it for good measure to hold them together. I lubed it with armor all and pulled it through. I attached a wire to the fire wall and had my dad pull out on it to free up the fuel line a little while I pulled it though.
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When I called the shop today for the fuel injectors, they were a week out. I head back to college on Monday and it’s a 7 hour drive away so I won’t be able to work on this again for a few months sadly. So I decided to try to free up the pintles in the injectors. I got them freed up and installed new lines on them two, put them in and decided to give it another try. Well it started Very Happy It has no exhaust so it’s a bit loud Laughing

Link

I also got the drive shaft re-attached today, I jacked up the front end to spin the wheels to realign it. I discovered that the front end feels nice and tight thankfully.

Also Go Westy and rock auto got a lot of my money today Laughing I’m getting new coolant hoses and pieces for it as well as a bunch of other parts it needs.

I’m loving this thing so far, I’m really happy I bought it. It’s way better than I thought it was.
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop
“Rome” 91 Syncro
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PostPosted: Fri Jan 03, 2025 3:12 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

Nice find and great work! I'd recommend that you replace the oil cooler o-ring. It is a known failure point and based on the condition of your oil filter it is something that should be done.

https://gowesty.com/blogs/schematics/oil-cooler-oil-pump-and-breather-tower
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PostPosted: Fri Jan 03, 2025 10:14 pm    Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild Reply with quote

termuehlen wrote:
Nice find and great work! I'd recommend that you replace the oil cooler o-ring. It is a known failure point and based on the condition of your oil filter it is something that should be done.

https://gowesty.com/blogs/schematics/oil-cooler-oil-pump-and-breather-tower


Thank you! Thanks for the tip and good to know! I added it to my list of parts to buy.

This morning I got the front frame patched. I pulled the one piece off that was barely hanging on. I flattened it out, drilled the spot weld holes bigger to weld and ground the edge smooth of the piece. I hit the pieces with weld through primer before welding them in place. I also welded the crack in the other side
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I did a temporary fix to a coolant leak it had and filled it with coolant so I could run it for a minute. We have a long driveway so I gave it a quick run to see how it did. The clutch feels great, brake stop good, it runs good, steers easy, shifts great, for sitting 20 years I was impressed how good it felt. It felt like it never sat, I was really impressed. The driveway isn’t long enough to get to 4th, but I got into every other gear, R,L,1,2 and 3rd and they all went in easy, were smooth, and they didn’t make any noise.
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Then I started on fixing the rust spot on the lower rear quarter. I formed a new panel for it and plan to weld it in tomorrow. Thankfully the structural part was solid. It looks like the pitting is worse but it was just the light I was using. I also have the small triangular part in the wheel well I need to replace.
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_________________
1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop
“Rome” 91 Syncro
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