It's been over a month since my last update, and there have been some developments. As I was nearing the end of dismantling the 1979 240D parts car, Mrs. MDG's car developed a new and unexpected problem. The power steering lines rusted through and started dumping fluid onto the exhaust rapidly.
When I investigated, I found that the lines in question were on the rack itself and that the rack needed to be pulled to replace them. The lines weren't cheap, either, costing well over $100 for the pair. Unfortunately, the steering rack and front subframe was just too rusted in place to justify attempting to repair it. So, I ended up looping the lines on the rack, thus temporarily converting the car to manual steering so that it can be driven temporarily.
Once that was done, I began a final marathon-like push to finish disassembling the 1979 and get it out of the way. I needed to get a "new" car for Mrs. MDG, but was out of space. Thankfully, I was able to get 95% of what I wanted off the parts car before calling a junk hauler to take it away.
The parts car is gone, but it will live on in the 1983 and other cars.
Then, I hit the classifieds and started car shopping.
I was willing to spend a bit more money for a more complete car, but in the end, the best car I found did need some work. I'll be bringing it home tomorrow. Until I get it home, no hints or videos as to what it is. All I'll say is that it's not a Subaru. I ended up buying something that I think will be more rust resistant.
Yesterday, I took a day off, as the "new" car isn't here yet, and went to Transporterfest 2013, a mostly VW bus show at the Larz Anderson Auto Museum in Brookline, MA. If you've never been there, I highly recommend the museum. It's really classy. The last time I went to that show was in 2011. Incidentally, that was the day that the Vanagon's original engine almost seized up on me.
I'll leave you with some final photos of the '79 and from the show yesterday.
First off, I apologize to anyone reading along for the long lapse in blog posts. I'll just put this out there - the Vanagon is running and back in service.
Shortly after my last blog post, I got it up and running again. Once everything was back together, I tried to start it. It certainly fought me, but eventually it did start and run. What's more, it's running well. There were a few hiccups, but nothing really required any readjustment. I've been driving it on and off for a few weeks now, including a traffic-filled trip across the city at rush hour to pick up a heavy TV.
It's running and driving very nicely with no additional signs of leakage. I'm happy. It wasn't an easy job, and was absolutely time consuming, but the results speak for themselves. I have yet to do any long distance driving.
When the van was done, I parked the Mercedes in the garage again. Despite sitting outside for two months and its condition, it started on the first bump of the key.
I want to get back to work on the project, but the garage was a disaster. A few weeks back, I picked up some free industrial shelves which will help me get a lot of stuff off the floor. I've thrown out several large bags of trash, and the garage is closer to being a real work space again. As usual, the garage would be done already if not for the fact that I had to work last weekend. It's unlikely I'll be able to do anything the next two weekends, either.
But, I will finish the garage and get back to working on the Mercedes. And, as I said, big things are in the works. What, you ask? You'll just need to stay tuned to find out.
I had a good, albeit prematurely-interrupted weekend with the Vanagon. I had to go in to the office on Sunday, so I knew that I'd only have Saturday to get things done. Even then, I had to give the Outback a little attention. Specifically, I had to do solidify an exhaust patch I made the previous weekend.
As soon as I was done with that, I turned my attention to the Vanagon. I knew all the "heavy lifting" was done. At this point, I just have to power through reinstalling the remaining bolt-on items. In short order, I reinstalled the thermostat housing, hooked up all the disconnected cooling hoses, finished installing the power steering pump, and installed the intake manifold.
At this point, all I need to do is install the throttle body and airbox, install a new oil filter, fill it up with oil and coolant, and then start it. Once it's running again, I'm planning to flush the cooling system before driving it again. If I hadn't had to work on Sunday, I'd probably be done. As it is, I'm hoping to wrench on it a bit this week and, with any luck, be able to drive it sometime this weekend.
Apologies to anyone who's been reading along. I've been busy the past few weeks and haven't had a chance to update the blog.
I was able to finish up and install the driver's side cylinder head. While I had it all apart, I opted to do the passenger's side head gasket, too. When I pulled the AMC head, I was surprised at how much pitting there was.
I got that side done and then reinstalled the rocker assemblies and pushrods (hopefully correctly). The pushrods can hang up a bit on installation. You need to be careful to properly seat the pushrod in the hydraulic lifter.
After that, I installed the exhaust. Not in one session, mind you... but more like piece-by-piece as time allowed. In the past month, work commitments, family commitments, and much-needed work on the daily driver Subarus have kept me from working on the Vanagon. Hopefully, I'm past that.
My (ambitious) goal is to have it back on the road for the 4th of July.
This past weekend, I finally got the exhaust off the van... without breaking anything. I had to cut some bolts. There were copious amounts of flame and penetrating oil involved. And my angle grinder.
But, I got the exhaust off. All the pipes survived and looked in good shape. I have new gaskets and a new bolt kit for when it's time to reinstall it. Once the exhaust was off and the cooling system was disconnected, I got to removing the driver's side cylinder head. I had everything disconnected and the head itself unbolted, including bagging and tagging all the small parts, in under a half hour.
Unfortunately, the head was stuck to the cylinders. On a Vanagon, the cylinders are 4 separate individual pieces from the actual engine block. I worked on it again Monday and Tuesday evening, which is when I eventually got the driver's side head to separate from the cylinders with some gently prying.
Once it was off, I got a good look at the cruddy, corroded surface. I cleaned it up last night (which helped a lot). Tonight, I filled the pitting with JB Weld (a common fix for this). Once it's cured, I'll sand it flat, and I'll be ready to start reinstalling the head on that side. When that's done, I'll start on the passenger side. Hopefully, that side will go more quickly.
Head separated from block
Head off block. Cylinders pushed back into water jacket.
Driver's side head off. Dirty and corroded. Need to clean it off.
Head cleaned up. Lots of pitting, but starting to look better.
Pitting filled with JB Weld. Still needs to cure so I can sand it flat.
As usual, I'm being kept away from working on the diesel. I'm currently replacing the head gaskets in the Vanagon. More accurately, I'm still working on disassembly. Long story short, the intake has to come off (it is currently off), the exhaust has to come off (working on that...), the coolant needs to be drained (not quite there yet), and the oil has to be drained (done) before I can remove the heads.
I had to go in to the office this past Saturday, which only gave me part of Sunday to work on the Vanagon. Hopefully, I'll get a lot more done next weekend. I'd like to have at least one of the heads off, and pending the condition of the head itself, I'd like to replace the gaskets on that side. Ideally, I'd like the van drivable before Memorial Day, so I can get back to work on the Mercedes.
They say there are two types of VW Vanagon owners. Those who have taken their engine out, and those who haven't taken their engine out... yet. Last year, I finally made it into the second category. When the original engine gave up on me in late 2011, I anticipated that the van would sit in storage for a few years while I saved my pennies for a more exotic engine swap (Subaru EJ22, Bostig Ford Zetec, etc). The van sat for less time than I originally thought.
In early 2012, I stumbled upon a local Craigslist ad for a used, running 2.1L VW waterboxer engine. It was dirty, and had sat for a year after being pulled (running) in favor of a Ford Zetec swap. I spent months of what little spare time I have replacing hoses, gaskets, and cleaning the engine up. As it came from an automatic Vanagon, I also had to swap over a few parts from my old engine to run this one with my manual transmission.
Anyhow, I crossed my fingers vis-a-vis the head gaskets. I could see that the passenger side had already been replaced. In July, I got the van to start, run, and drive again. I've driven it sparingly in the past year, but learned early on that the driver's side head gasket had a leak. I tried a few stop leak products that only slowed it down.
So, now that the Outback is on the road and reliable, I'm starting in on the head gasket job. I'm going to try replacing them without taking the engine out again, and hope to have the job done in under a month. Once again, I work slowly and have limited time to do the job. The new engine does run well otherwise. The leak is external, and the oil and coolant weren't mixing. I can't wait until it's done and reliable again, so I can take it camping.
Hopefully, I'll have it done before Memorial Day. I bought the Vanagon in late May, 2003, so next month will mark ten years. I can't think of a better way to mark the occasion than to drive it again.
As of my last post, I had just gotten my daily driver Legacy back on the road after a cylinder head replacement. All went well there, and the car has been back in daily service, seeing around 90 miles per day since then.
So, now that I had transportation again, I decided to get back to working on the Vanagon again. I spent the next few weekends working on it, starting with installing the flywheel on the new engine. Eventually, I got the engine bolted into place and installed.
Finally, last weekend, I got the engine to start, albeit briefly. It doesn't seem to be getting fuel, so I suspect that either the fuel pump went bad from sitting dry for six months (I drained the gas tank when I put the van into storage), or there's a blockage somewhere. I need to do further diagnosis.
But, here's a video of it starting on starting fluid (sounds pretty good for an engine that sat for at least a year and a half):
I would have done more diagnostics this weekend, but I was busy with something else... As you may remember from previous posts, I've been looking for a new car for my wife for quite some time now. I finally found it, and it's something familiar:
No, you're not looking at my 1995 Legacy. This is my wife's... 1995 Legacy. Actually, the only difference between the cars is that hers has an automatic transmission, fewer miles on it (115,000), and has a working air conditioner. I didn't buy the same exact car on purpose. It was just the first decent 2.2L Legacy I've seen in my price range in a while. I've been buying tune-up and repair parts all week and will be working on this car shortly. Once it's done, I'll be selling the 320,000 mile green Impreza.
Apologies to anyone who's been reading in the past six weeks looking for updates on my regular projects. I really haven't touched the Vanagon or the 240D since early April. I've been busy with the Legacy.
Right around the time of my last blog post, the Legacy started running poorly and throwing a P0302 trouble code. I threw a few parts at the car, hoping it would be a simple fix (spark plugs, wires, a new coil, and finally, a fuel injector). None of this changed how the car ran, and no matter how many times I reset it, the code kept coming back.
So, after throwing money down the drain on non-returnable parts I didn't need, I did what I should have done in the first place - I ran a compression test:
The results were conclusive, showing low compression in cylinder 2 as the cause of the misfire. From the specifics of the test, it looked like a burned exhaust valve or a worn valve guide was likely the cause of the problem. So, after some brief soul-searching, I decided to go ahead and repair the car. The clearest path to that goal was replacing the cylinder head. Learning how to do that was enough without having to learn how to rebuild it myself.
I ordered a rebuilt cylinder head from F&S Auto Parts in Roxbury, CT, who I found highly recommended on several Subaru message boards. They rebuild cylinder heads to order, so I had to wait a little over a week for the part. In that time, I did something I hate to do - I commuted to work by train. Frankly, it's crowded, overpriced, uncomfortable, and the schedule is horrible. But, at least I was able to get to work.
For a while, I felt like an urban redneck. I had three cars at home, none of which I could drive. Finally, my cylinder head arrived, but not without difficulty. Let me paint a picture for you...
It was a sunny Saturday morning, around 11 AM. I was home, and, anticipating the arrival of the cylinder head, I went to look out the front door to see if the local mail carrier was on our street yet. I saw no sign of the mail truck, but found the day's mail in the mailbox, along with an attempted delivery notice indicating for my cylinder head. I needed the part, and in a panic, tried calling the post office (I got no answer). Not knowing what else to do, I started searching the neighborhood in my wife's car, looking for the mail carrier. I found a succession of trucks and carriers, none of whom were my mail carrier, but who were all helpful. Finally, one of them directed me to a street around a half mile away from my house, where I found another truck. I waited like a madman (as politely as I could) for the carrier to return. When she did, I was happy to find that she had the cylinder head, and was happy to let me have it just so long as I signed the delivery notice.
My prize in hand, I sped back to the house and started tearing into the Legacy. By the end of the day, I had the intake manifold off. By the end of the weekend, the new cylinder head was installed, but the engine wasn't buttoned-up yet. By the middle of that week, I had the car back on the road, running better than it ever had since I bought it.
So, on top of that, another weekend that I was horribly sick, and this past weekend, when I replaced a CV axle on my wife's car:
...I haven't had any time for the Vanagon.
But, I've budgeted most of the upcoming long weekend to wrench on the van. I am still planning on having it back on the road for the summer.
Egad! It's been nearly a month since I updated the old b-log. And what an unfortunately eventful month it's been.
I'm not going to beat around the bush. The Vanagon is dead. Well, "mostly dead" anyway, to steal a line from Billy Crystal. As per my last post, I was having suspected oil pressure problems. I plumbed in a gauge and drove it locally a bit. Everything seemed more or less OK. I even attempted to install a tachometer:
The results of the second oil pressure test with the tach installed were inconclusive, due to poor quality aftermarket gauges. So, I decided to drive a little more locally to test the van. I was planning a trip to New Jersey, which should have happened this past weekend, and wanted a few more local miles under my belt before I took a long trip in the van. So, a week and a half ago, I decided to take the Vanagon to Transporterfest, a VW bus show at the Larz Anderson Auto Museum in Brookline, MA.
The van handled the first part of the trip OK, but as it really heated up at highway speed, the oil pressure began to drop. By the time I got there, the light was going off intermittently. Not a good sign. So, I enjoyed the show, and when it was over, I decided to head home. It was a 40 mile trip there and back. Well... I didn't make it back. Actually, not true. I did make it back home, but with the help of AAA and a ride from my wife:
Long story short, the van will probably start, but a scant 300 miles or less since I completed all the work, and the engine is pretty much dead. As I don't have the money to fix it (yet), I de-registered it, de-insured it, and am preparing to get it into the garage for long-term storage.
Bottom line, I don't want to sell the van. I don't need to, and in its current mechanical condition, it probably wouldn't sell for much. So, I'm a bit sad. After almost eight and a half years, the van is no longer usable. But, this is where we get to the point of this particular blog post.
In the past, every time I've had major car problems, I've learned something or otherwise gained from the experience. Conscious of that trend, I'm trying to take as many positives out of this experience as possible.
Most of all, I'm going to use this to complete a long-time goal of mine and learn how to swap a Subaru engine into the van. Once I can save enough money for the conversion parts, I'll be dropping in a Subaru EJ22 engine, just like in my Legacy. I know the engine very well - even better than I know the Vanagon's engine at this point. Putting one in a Vanagon, though... that's going to be a learning experience.
But, it'll be a long while before I have the money for the project. So, in the meantime, I'm going back to working on the Mercedes 220D project. I dug it out this past weekend:
It hasn't even been started since April, 2010. I'm hoping to have it running again this weekend so I can get it out of the garage and clear up that space for the Vanagon. I'll be resuming work on the Mercedes outdoors. As much as I didn't want to work outdoors in the winter again, I'd prefer to do that rather than leave the VW outside. When it's done, I do plan to enjoy it a bit, but will eventually sell the Mercedes to help fund the Vanagon engine swap.
Since my last blog post, I was actually able to finish work on the Vanagon. Overall, it shouldn't have taken this long to get it done, but life has a way of interfering with my free time. What, specifically, you ask?
First off, the Subaru's alternator failed on me:
and I fixed it:
and the bearing in the new one went bad two weeks later, necessitating another replacement:
Oh, and there was Hurricane (err... Tropical Storm, that is) Irene:
Plus there's the usual routine maintenance around the house and on the cars, as well as my day job to keep me busy.
So, this weekend, I finally got the van together and was able to take it out for a good 30 miles. I ran some fuel injector cleaner through it and it's purring like a kitten now:
I can't convey with pictures how much cleaner it is inside and out. Even before all the work, it photographed pretty well, even when dirty. You'll just need to take my word that this is actually a major improvement. The looks now approximate the way they were when I was regularly taking the Vanagon to shows years ago. Mechanically, it's pretty much there, too.
Here's a walkaround:
I'm happy. I hope to still make it to a show or two this year. Now that the van is done, I plan to take care of a few bodywork-related items on the Legacy and my wife's Impreza (rust spots). Once the Subarus are done and ready for the winter, I'm going to start back in on the Mercedes 220D.
It's been a couple of months since I touched it, and I'm eager to get back to working on it.
As of my last blog post, I've covered all the cars I've owned. So, as you can see, I'm a car nut, and a do-iy-yourselfer. I'd much rather tackle a repair job myself than pay someone else and trust that they'll get the job done right and not rip me off. With 100-ish miles of driving daily each between my wife and myself, routine repairs and maintenance add up quickly.
The downside of this is that I have little free time for anything other than fixing my cars.
The upside of this is that I have plenty to film and write about for you fine folks.
With so much on my plate, my projects need to be handled in order of priority. Sometimes, one car gets a bit neglected in favor of a needier one. That's just the way it works out.
If you've been following my blog, you know that my second car was the Vanagon. I bought it back in 2003 and it's currently the second place record holder for the car I've owned for the longest amount of time. The first place record holder is still my first car - the 1982 Mercedes 240D, which I had for a hair shy of nine years. The Vanagon will assume the first place slot next Spring. Despite this, it's also the car I've driven the least (only counting among cars I registered and actually drove). Although I do take it camping and use it for hauling on Home Depot runs, it's in pretty amazing shape for its age, and I've tried my best to keep it that way, despite living in New England.
Shortly after buying the van, I joined a VW club. My original motivation was to meet some people who knew about these vans and maybe abosrb some knowledge to help me fix the van myself. I really liked the group. The club is now somewhat defunct. We were all in the same age bracket, and over time, we've all been less active on the car "scene" as we've moved away, gotten married, or miscellaneous. We're all still good friends and in touch, though.
Anyhow, although I didn't learn anything maintenance-wise from the group, we had a lot of fun, and attended a lot of car shows together. Eventually, they convinced me to start entering the van into shows. I didn't think the van was show-quality, but others disagreed. I entered the van into competition for the first time at H2O International in Ocean City, MD, in 2003, and walked away with first place in my category. I kept entering it in shows and I kept winning for two reasons:
Almost nobody brings Vanagons to these shows. I had very little competition in my category.
When I did have some competition, I usually won. The van is just that nice.
Of course, it's been more than a few years now since I showed the van competitively. Other projects got in the way, and New England weather and road salt started to take a toll on it. This past winter, as my Jetta was constantly breaking down, I drove the van a lot, which I hate to do in the winter. It handles poorly in the snow and I hate exposing it to road salt.
I knew the van was dripping oil, but the drip had gotten much worse. On top of that, the van was dirty and grimy in and out, and very small surface rust spots which I'd ignored for years were really starting to bother me. So, as soon as the "new" Subaru was on the road, I got serious about repairing the van, and bringing it back to a condition approximating the way it was when I bought it.
First up, I tackled the oil leak. I replaced a bunch of oil seals, but the problem turned out to be one of the oil pressure sensors, which had developed a large leak. After that, I got to the bodywork. I pulled a dent that had been on the van since before I bought it (back in 2003, I simply Bondo-ed over the dent) and did some touch-up painting. I also removed the surface rust spots and coated those areas in Miracle Paint before applying the final touch-up paint. I also pulled the bumpers and brush guard for repairs and touch-up painting.
When all that was done, I gave the interior a massive cleaning, including all the interior glass, which hadn't had a good cleaning in a couple of years. As of this blog post, I'm not done, but am NEARLY done. I still need to do a final bits of touch-up on the brush guard and need to give the van a good wash and wax.
But, when I'm done, the van will once again be a pleasure to drive, and I hope to take it to a show or two this season yet.
(before - old touch-up paint failing and seam rust showing)
(Bondo ground away and dent PROPERLY pulled)
(completed repair - light gray on left is dust)
(rear emblem chrome had flaked off - repainted it black)
