Just some tips and observations based on being about half-way through completely replacing the cooling system on my '87 Westfalia with manual trans and A/C. This job has to be one of the more tedious and time-consuming ways in which one can interact with one's vanagon. I can see why the inline-4 engine conversion is so popular. Just simplifying the cooling system is almost worth doing the conversion. The wbx with air conditioning is particularly challenging. 1) The use of hose clamp pliers, as opposed to struggling with regular pliers, makes a huge difference on some of the more difficult spring clamps. I used pliers with a toothed device for holding the jaws in specific position, again nice to have with the larger spring clamps. Got mine at the local Kragen's, about $14. 2) I found that it was easier to replace the oil cooler hoses, as well as the water pipe that comes from the thermostat, BEFORE installing the water pump. It's necessary to get the hoses positioned on the cooler just right, and them clamped, and the water pump is in the way when doing this. 3) I replaced the oil cooler O-ring. However, before fully tightening the nut that secures it, I left it loose enough so that the cooler could rotate. It was easier to maneuver the two small elbow hoses into position on the cooler this way. There isn't much room to work. 4) The thermostat housing is easier to install into position by first installing the lower half, installing all clamps, installing the thermostat, and then installing the upper half. I tried to install the whole thing already assembled, but it's too bulky to maneuver into position. I also changed out the two temp senders while it was out. 5) The hose that goes from the right-hand cylinder head to the plastic TEE junction (S-shaped hose) runs very close to the #1 cylinder exhaust pipe. My old hose had split at this location, which was what prompted me to undertake this project in the first place. I suspect that excess heat broke the hose down at this point. The new replacement hose is EPDM, which I believe is more heat resistant than plain rubber. I'm thinking of also wrapping this particular hose in aluminum foil to reflect the heat of the exhaust pipe away from it. More insights as I gain them :) dan |
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