Date:         Tue, 8 Sep 2009 09:32:47 -0400
Reply-To:     mcneely4@COX.NET
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dave Mcneely <mcneely4@COX.NET>
Subject:      go over for '91 camper, mechanical soundness and reliability
Content-Type: text/plain; charset=UTF-8; format=flowed; delsp=no

When I wrote the following, I was seriously asking for help in making
sure I addressed all the things needed to make my camper mechanically
sound and reliable.  So far, several people have responded, but none
have offered any comments as to what if anything more I should do to put
the beast into the state of reliability a good many on here seem to
think should be expected.  This is a plea -- what more should be
addressed?

Oh, I did not list originally the exhaust system, but I have inspected
it, and in addition to all the things mentioned below, I have replaced
the short length of exhaust pipe distal to the muffler (twas rusted).
Otherwise, exhaust system seems sound, including catalytic converter.
BTW, for those who have reported on converters that were clogged, and
that they gutted:  I hope the gutting was a temporary expedient and that
you have or will be soon replacing the no longer functional units.


On Mon, Sep 7, 2009 at 1:29 PM , Dave Mcneely wrote:


my van is a '91 Vanagon GL Campmobile that I bought in April of this
year.
>
> Oh, I guess what I need is a list of all the do-overs that I need to
> do
> to make sure my vanagon mechanical systems are all sound.  Let's see
> --
>
> I've got a nearly new rebuilt engine (22k miles.  chassis has 145k
> miles).
> Transmission drained and refilled (manual transmission).
> I've redone all the ignition parts -- plugs, points, rotor, cap,
> wires.
> New air filter.
> New fuel injection lines (they were part of the engine rebuild).  New
> fuel filter and new fuel lines from tank to filter and filter on.  New
> fuel pump.
> New AFM.
> five New heavy duty tires, Kumho 857s: 195R14C.  More than meet specs
> for weight capacity (load level D, spec is for C), 8 ply rating.
> tires
> come with lifetime rotate and balance, including spare.  I'm a nut
> about
> keeping this up on all my vehicles.  Van drives well with these tires.
> Run these at 53 psi rear, 43 psi front per VW spec.  Tire spec allows
> up
> to 65 psi, which I will go with if I think I may be carrying the
> maximum
> weight.
> Brakes inspected, fluid flushed and refilled, and good to go.
> Alignment (but, was unaware that one needs (according to some of you
> guys) to load the vehicle before doing the alignment, do the
> alignment,
> drive it, do the alignment again).  Wow.  Of course, that's not
> DIFFICULT.  Fortunately, mine drives with the steering wheel dead on
> center, and will track absolutely on a straight, level road, whether
> loaded or not.  Good enough?  It is considered so on most vehicles.
> New cv joints.  New ball joints, upper and lower.  Shocks check as
> excellent (fairly new).  No steering play, no vibration or bounce.
> Wheel bearings good, newly greased.
> New radiator, new radiator temperature switch.  Complete flush.  New
> phosphate free coolant with distilled water (the expensive VW stuff,
> probably not necessary, but ............ ).  New temperature sender.
> Fan motor hot post repaired where broken during radiator replacement.
> New coolant distribution manifold (the one that reportedly fails
> catastrophically.  Mine broke during another repair, so not so
> catastrophic).
> Plan to redo all coolant hoses, and plastic pipe ends, pending new
> funds.
> New water pump (twice, due to failure of first new one).  New
> thermostat.
> New oil pump (not needed, mistake).
> New motor mounts.
> New drive belts.
> Oil pressure monitoring system redone, including new sensors, new wire
> to gauge and instrument cluster.  Idiot light and gauge both working
> properly (gauge reads about 5 lbs lower than actual according to
> independent mechanical check).  BTW, pressure senders set up on a
> single
> tube (with a T) from the engine case for both high and low pressure,
> eliminating the difficult to access high pressure sender location.
> Senders and tube secured with a bracket to engine case to minimize
> vibration.
> Currently running Valvoline 50W due to extreme summer temps in some
> areas I've been driving.  Will change to multi-vis (15W-50 if I can
> get
> it, otherwise 20W-50 Castrol) next month or so with cooler weather.
> If
> I decide to drive during winter, and can't get the 15W-50, I may go
> with
> 10W-40, or with 30W.
> Clutch engages and disengages well.  No idea when it was redone, if
> ever.  Evidently not with engine replacement, as paperwork does not
> reflect it.
> New wiper blades and rear hatch struts.
> Very slight leak from oil cooler, will replace o-ring at next oil
> change
> (not leaking enough to spot under the vehicle, and not enough to
> require
> adding oil between changes).
> I carry spare fuses and bulbs, and spare drive belts.  Guess I'll get
> some of that "Rescue Tape."
>
> I keep my AAA card and cell phone handy.
>
> What have I missed?
>
> Dave Mc