Date:         Wed, 3 Mar 1999 11:20:27 -0800
Reply-To:     Tom Clein <tomkat@ISOMEDIA.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Tom Clein <tomkat@ISOMEDIA.COM>
Subject:      Fresh Air Fan Blower (long)
Content-type: text/plain; charset="US-ASCII"

I DID IT!

I know this will sound like an Oscar acceptance speech...but I
couldn't have done this without the help of Joshua Van Tol, Darren
Sieben & others (you know who you are!).   A special thank-you to
the archives (what a wealth of information!) and to Werner
Schirmer for posting a clearer/better procedure for Blower Fan
Re/Re than Bentley on Jan 8, '97 (Post #22476?).

I was able to remove steering column 'shear' bolts with ViseGrips
and re-use.  FLAP (what does that stand for, anyway?) could only
find one shear bolt (in NJ?)...also got 8 clips to put 'box' back
together.  Got new motor from Bus Depot for $100.  I did find a
complete 'ventilator box' from a '91 Vanagon from wrecking yard
for $50 (I extract)...so I had the pleasure of pulling 2 dashes,
cracking open 2 ventilator boxes in 1 week!  Now I've got heated
air out of side dash vents in my '87!  Cool! (or Hot...depending
on how you look at it).

When I opened my 'old' '87 ventilator box (@$#!%*& plastic welds
were a real pain!) found that resister had partially melted
plastic around it while trying to turn seized motor...concluded
that was 'burning' smell accompanying non-working blower....gotta
be careful about that!

Also lubed up all heater control cables, used sewing machine oil
on new fan motor before installation, replaced burned out bulbs
(now have light over Syncro panel), cleaned out 'new' ventilator
box, checked front heater core (good shape)...checked all grounds,
wired new larger, door speakers and amplifier (with new moisture
barrier); checked for windshield leaks/rust...mounted/wired fog
lights ($30 from Shuck's) to improve low-beam visibility (found
another Rear Window Defogger switch (from same wrecking yard)
works great - inverted switch in console so I can tell them
apart-will probably dab different color paint on indicator bulb as
well).  Also, thanks to list member who suggested mounting
additional map pocket ~3" back from screw holes on passenger-side
door panel (so you can open glove box!)

Anyway, about 8 hours worth of labor...including pulling dash/box
out of '91.  I did have to bring in to my usual service place to
have cooling system flush/fill (been 2 years anyway...I don't do
this at home - have 2 dogs who might OD on antifreeze and I've no
way to safely/environmentally flush).

Before tackling fan motor job, I had a loose fan belt and
evidently cracked the @#!$&* PLASTIC flange from right side head
to expansion tank while tightening belt.  FLAP charged me $28 for
metal replacement flange...I lost about a gallon of coolant; at
least that's how much distilled water I put in (several times) on
way to service - to keep coolant level light from flashing.

Service place was very impressed that I changed fan motor myself
(and with the supporting cast of all you list members!)-figured I
saved ~$600.

I'm feeling so confident that I'm going to pull dash on
father-in-law's '91 Syncro Westy (I know - I must be some kind of
masochist to want to do this AGAIN!) to rid him of his Mice
infestation/smell problem which has plagued him since new (I'll
seal up openings around sides of fresh air intake grill to prevent
re-infestation - thanks to another list member/archives for that
advice).  I'll probably replace his fan motor as well...since it
sounds like it'll go sooner rather than later - when he needs it
most!

Thanks again for all your help (plural!).

Next 'TOYBOX' job...passing emissions in Aug with a trashed
Catalytic Converter, rusted out muffler/tailpipe and (I've been
told) bad fuel injectors/O2 sensor!

WA State makes you fail test, spend min. $150 with a 'certified
emissions control specialist', fail re-test, visually inspect all
emissions systems for tampering - before issuing waiver.  PO's
have been getting waivers since '93 doing this.  I'd like to be
more environmentally conscious - can't register w/o emissions
certificate - also can't sell without emissions cert. - so I'm
kinda stuck with spending $$$.

FLAP wanted $1,000 to replace Cat/Muffler/FI's/O2 sensor 2 yr's
ago (after charging me $300 for major emissions tune-up).  I think
I'll fail test 1st - check/replace O2 sensor, Catalytic
Converter/Muffler (with new from list vendor) - have 'certified
emissions control specialist' set to specs (spend $150?) re-test -
then only change FI's myself if fails retest.  Thanks to Darren
Sieben for his advice.

Sorry about the bandwidth use...just so full of it (HOT AIR!) and
thankful for all your help!  See you on the road...with working
defroster!

Tom Clein
'87 Syncro Westy 'TOYBOX'