'Tool Box' Syncro

`Tool Box' Syncro ?

This is the affectionate name given to my lastest 2.1 liter 1989
digifant Syncro, simply because it is always full of tools…

This is the van I bought on the day of the Shallow Xing trip. So much
has happened or has been done to this Syncro and I have learnt a lot
about how the digifant runs.

I have attempted to put it all down in writing since all of us can
learn a lot about fault finding and how to fix it scenarios.

In chronological order:

1: Handed over the cash. It was running on LPG. Previous owner said
that he never ran it on petrol. The petrol tank was empty. I drove
away (on LPG) with my new car.

2: Filled her up with petrol. Would not run on petrol at all. Hmmm…
think I suspected that would be the case.

3: I now have a spare engine from my Subaru transplant operation in
my camper Syncro. Lots of spares and a great opportunity to find out
what was wrong with the tool box Syncro.

4: Replaced the injectors. Van started on petrol. No power, rich
mixture. Stalled and generally was quite sick.

5: Removed air flow sensor. The vane was bent and seized rock solid
(probably having been blown up by a gas backfire (from previous owner
always starting on LPG).

6: Replaced air flow sensor although I retained the air flow sensor
circuit board. The carbon track wears. Took resistance readings. The
two boards gave very different readings.

7: Car ran a lot better. Still no power. Cleaned air filter and
replaced fuel filter. A lot better. Replaced the fuel regulator and
it ran better again.

8: Few times had trouble starting. Replaced the plugs and cleaned the
dizzy cap. Started first time every time.

9: Still running rich and had a hiccup after engine reached operating
temperature.
Checked Oxygen sensor and was only outputting 0.3 volts (at op.
temp). Replaced and `new' O2 sensor had about 0.9 volts. Quite a
difference. Fixed the mixture problem and the hiccup disappeared.

9: Test drive and suddenly very erratic behavior. Cleaned all
connections with CO contact cleaner and re did all earthing points.
Did not miss a beat until…

10: Low coolant light came on. Immediately stopped and no coolant at
all. None on the ground none in the tank hmmm where did it all go?
Inside the engine!

11: Head stud corroded through and head nut became loose. Direct path
for coolant to enter the engine.

12: Towed home (very humbling). Drained engine and coolant.
13: Removed head and spent about 2 days removing broken stud from
casing. A particularly nasty job. Used a 8mm tube socket, cut a notch
on the side and TIG welded it onto the 5mm of protruding stud. Then
applied a lot of heat to the casing with MAP gun and the stud came
out. All done with engine still in car (see….it can be done!).

14: Removed and cleaned all the valves and ports. Replaced head
gaskets and O rings

15: Adjusted valves.

16: Flushed engine with 50:50 mix of kerosene and cheap engine oil
for 60 secounds run time.
17: Flushed cooling system using half a cup of phosphate free
dishwasher powder (mixed with water of course).
17: Flushed engine with cheap oil for 5 minutes run time.
18: Replaced oil filter and added cheap oil. Ran for about 250 kms.
19: Added oil cooler and remotely mounted filter in side engine bay.
This old girl (330,000kms) runs hot (we have had very hot weather as
well). And the oil cooler certainly helps.
20: 14 full days work and two cases of beer…
21: The `tool box' Syncro is purring along like new!

And thanks to Rick who gave up a few days of his holiday to
help...mind you working on a Syncro is better than a holiday :-)

Regards to all

Peter
Peter,
 
Very informative and a very valuable example of progressive problem solving.
 
Thanks for posting this for the benefit of all.
 
Les
 
 
----- Original Message -----
From: Peter
Sent: Thursday, February 12, 2009 4:02 PM
Subject: [Syncro_T3_Australia] 'Tool Box' Syncro

`Tool Box' Syncro ?

This is the affectionate name given to my lastest 2.1 liter 1989
digifant Syncro, simply because it is always full of tools…

This is the van I bought on the day of the Shallow Xing trip. So much
has happened or has been done to this Syncro and I have learnt a lot
about how the digifant runs.

.

Thanks Peter, I enjoyed this too!

Do you have any more details of the oil cooler you added? I have a 1.6TD and apparently they benefit from the addition of an oil cooler as they run pretty hot too.

I'm in the early stages of investigating what to do and i like the idea of not having to run the pipes all the way to the front which sounds like what you did if you kept it in the engine bay.

Cheers
Gary


[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyone.net
www.twentytwentyone.net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782

On 12/02/2009, at 4:16 PM, Les Harris wrote:


Peter,
 
Very informative and a very valuable example of progressive problem solving.
 
Thanks for posting this for the benefit of all.
 
Les
 
 
----- Original Message -----
From: Peter
Sent: Thursday, February 12, 2009 4:02 PM
Subject: [Syncro_T3_Australi a] 'Tool Box' Syncro

`Tool Box' Syncro ?

This is the affectionate name given to my lastest 2.1 liter 1989 
digifant Syncro, simply because it is always full of tools…

This is the van I bought on the day of the Shallow Xing trip. So much 
has happened or has been done to this Syncro and I have learnt a lot 
about how the digifant runs.

.
 


Hi Peter,

 

Congratulations on getting her running again. Most people just throw their hands in the air when a head stud drops like that. Were the other studs OK, or did you have to replace them as well?

Here’s hoping you know have reliable back up transport while your Subaru conversion is completed, and long beyond.

 

BRIAN REED

FAIRFIELD NATURAL THERAPIES

185 Wingrove St

Fairfield, Vic. 3078

03 9481 5673   0407 319 521


From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of Peter
Sent: Thursday, 12 February 2009 4:02 PM
To: Syncro_T3_Australia@yahoogroups.com
Subject: [Syncro_T3_Australia] 'Tool Box' Syncro

 

`Tool Box' Syncro ?

This is the affectionate name given to my lastest 2.1 liter 1989
digifant Syncro, simply because it is always full of tools…

This is the van I bought on the day of the Shallow Xing trip. So much
has happened or has been done to this Syncro and I have learnt a lot
about how the digifant runs.

I have attempted to put it all down in writing since all of us can
learn a lot about fault finding and how to fix it scenarios.

In chronological order:

1: Handed over the cash. It was running on LPG. Previous owner said
that he never ran it on petrol. The petrol tank was empty. I drove
away (on LPG) with my new car.

2: Filled her up with petrol. Would not run on petrol at all. Hmmm…
think I suspected that would be the case.

3: I now have a spare engine from my Subaru transplant operation in
my camper Syncro. Lots of spares and a great opportunity to find out
what was wrong with the tool box Syncro.

4: Replaced the injectors. Van started on petrol. No power, rich
mixture. Stalled and generally was quite sick.

5: Removed air flow sensor. The vane was bent and seized rock solid
(probably having been blown up by a gas backfire (from previous owner
always starting on LPG).

6: Replaced air flow sensor although I retained the air flow sensor
circuit board. The carbon track wears. Took resistance readings. The
two boards gave very different readings.

7: Car ran a lot better. Still no power. Cleaned air filter and
replaced fuel filter. A lot better. Replaced the fuel regulator and
it ran better again.

8: Few times had trouble starting. Replaced the plugs and cleaned the
dizzy cap. Started first time every time.

9: Still running rich and had a hiccup after engine reached operating
temperature.
Checked Oxygen sensor and was only outputting 0.3 volts (at op.
temp). Replaced and `new' O2 sensor had about 0.9 volts. Quite a
difference. Fixed the mixture problem and the hiccup disappeared.

9: Test drive and suddenly very erratic behavior. Cleaned all
connections with CO contact cleaner and re did all earthing points.
Did not miss a beat until…

10: Low coolant light came on. Immediately stopped and no coolant at
all. None on the ground none in the tank hmmm where did it all go?
Inside the engine!

11: Head stud corroded through and head nut became loose. Direct path
for coolant to enter the engine.

12: Towed home (very humbling). Drained engine and coolant.
13: Removed head and spent about 2 days removing broken stud from
casing. A particularly nasty job. Used a 8mm tube socket, cut a notch
on the side and TIG welded it onto the 5mm of protruding stud. Then
applied a lot of heat to the casing with MAP gun and the stud came
out. All done with engine still in car (see….it can be done!).

14: Removed and cleaned all the valves and ports. Replaced head
gaskets and O rings

15: Adjusted valves.

16: Flushed engine with 50:50 mix of kerosene and cheap engine oil
for 60 secounds run time.
17: Flushed cooling system using half a cup of phosphate free
dishwasher powder (mixed with water of course).
17: Flushed engine with cheap oil for 5 minutes run time.
18: Replaced oil filter and added cheap oil. Ran for about 250 kms.
19: Added oil cooler and remotely mounted filter in side engine bay.
This old girl (330,000kms) runs hot (we have had very hot weather as
well). And the oil cooler certainly helps.
20: 14 full days work and two cases of beer…
21: The `tool box' Syncro is purring along like new!

And thanks to Rick who gave up a few days of his holiday to
help...mind you working on a Syncro is better than a holiday :-)

Regards to all

Peter

Thank you Peter
that was great. Im getting more scared of my Syncro everyday. I have had some of the same problems over the past 8 months. VAn running now, but coughs at first running then goes fine. Just dont have the funds to go any further. Thnk you again for sharing
Robert

--- On Thu, 12/2/09, Peter <kestel.p@bigpond.com> wrote:
From: Peter <kestel.p@bigpond.com>
Subject: [Syncro_T3_Australia] 'Tool Box' Syncro
To: Syncro_T3_Australia@yahoogroups.com
Received: Thursday, 12 February, 2009, 12:02 AM

`Tool Box' Syncro ?

This is the affectionate name given to my lastest 2.1 liter 1989
digifant Syncro, simply because it is always full of tools…

This is the van I bought on the day of the Shallow Xing trip. So much
has happened or has been done to this Syncro and I have learnt a lot
about how the digifant runs.

I have attempted to put it all down in writing since all of us can
learn a lot about fault finding and how to fix it scenarios.

In chronological order:

1: Handed over the cash. It was running on LPG. Previous owner said
that he never ran it on petrol. The petrol tank was empty. I drove
away (on LPG) with my new car.

2: Filled her up with petrol. Would not run on petrol at all. Hmmm…
think I suspected that would be the case.

3: I now have a spare engine from my Subaru transplant operation in
my camper Syncro. Lots of spares and a great opportunity to find out
what was wrong with the tool box Syncro.

4: Replaced the injectors. Van started on petrol. No power, rich
mixture. Stalled and generally was quite sick.

5: Removed air flow sensor. The vane was bent and seized rock solid
(probably having been blown up by a gas backfire (from previous owner
always starting on LPG).

6: Replaced air flow sensor although I retained the air flow sensor
circuit board. The carbon track wears. Took resistance readings. The
two boards gave very different readings.

7: Car ran a lot better. Still no power. Cleaned air filter and
replaced fuel filter. A lot better. Replaced the fuel regulator and
it ran better again.

8: Few times had trouble starting. Replaced the plugs and cleaned the
dizzy cap. Started first time every time.

9: Still running rich and had a hiccup after engine reached operating
temperature.
Checked Oxygen sensor and was only outputting 0.3 volts (at op.
temp). Replaced and `new' O2 sensor had about 0.9 volts. Quite a
difference. Fixed the mixture problem and the hiccup disappeared.

9: Test drive and suddenly very erratic behavior. Cleaned all
connections with CO contact cleaner and re did all earthing points.
Did not miss a beat until…

10: Low coolant light came on. Immediately stopped and no coolant at
all. None on the ground none in the tank hmmm where did it all go?
Inside the engine!

11: Head stud corroded through and head nut became loose. Direct path
for coolant to enter the engine.

12: Towed home (very humbling). Drained engine and coolant.
13: Removed head and spent about 2 days removing broken stud from
casing. A particularly nasty job. Used a 8mm tube socket, cut a notch
on the side and TIG welded it onto the 5mm of protruding stud. Then
applied a lot of heat to the casing with MAP gun and the stud came
out. All done with engine still in car (see….it can be done!).

14: Removed and cleaned all the valves and ports. Replaced head
gaskets and O rings

15: Adjusted valves.

16: Flushed engine with 50:50 mix of kerosene and cheap engine oil
for 60 secounds run time.
17: Flushed cooling system using half a cup of phosphate free
dishwasher powder (mixed with water of course).
17: Flushed engine with cheap oil for 5 minutes run time.
18: Replaced oil filter and added cheap oil. Ran for about 250 kms.
19: Added oil cooler and remotely mounted filter in side engine bay.
This old girl (330,000kms) runs hot (we have had very hot weather as
well). And the oil cooler certainly helps.
20: 14 full days work and two cases of beer…
21: The `tool box' Syncro is purring along like new!

And thanks to Rick who gave up a few days of his holiday to
help...mind you working on a Syncro is better than a holiday :-)

Regards to all

Peter



Make Yahoo!7 your homepage and win a trip to the Quiksilver Pro. Find out more.
Gday Peter,

Brilliant post, I reckon your dedication, persistance, enthusiasm and
ingenuity well and truly shows through here with this project, I suspect
many of the rest of us Oz syncro list members are indeed envious of your
abilities, in particular your inspired doggedness at problem solving.

Great stuff Dr. Syncro.

Cheers.

Ken



--- In Syncro_T3_Australia@yahoogroups.com, "Peter" <kestel.p@...>
wrote:
>
> `Tool Box' Syncro ?
>
> This is the affectionate name given to my lastest 2.1 liter 1989
> digifant Syncro, simply because it is always full of tools…
>
> This is the van I bought on the day of the Shallow Xing trip. So much
> has happened or has been done to this Syncro and I have learnt a lot
> about how the digifant runs.
>
> I have attempted to put it all down in writing since all of us can
> learn a lot about fault finding and how to fix it scenarios.
>
> In chronological order:
>
> 1: Handed over the cash. It was running on LPG. Previous owner said
> that he never ran it on petrol. The petrol tank was empty. I drove
> away (on LPG) with my new car.
>
> 2: Filled her up with petrol. Would not run on petrol at all.
Hmmm…
> think I suspected that would be the case.
>
> 3: I now have a spare engine from my Subaru transplant operation in
> my camper Syncro. Lots of spares and a great opportunity to find out
> what was wrong with the tool box Syncro.
>
> 4: Replaced the injectors. Van started on petrol. No power, rich
> mixture. Stalled and generally was quite sick.
>
> 5: Removed air flow sensor. The vane was bent and seized rock solid
> (probably having been blown up by a gas backfire (from previous owner
> always starting on LPG).
>
> 6: Replaced air flow sensor although I retained the air flow sensor
> circuit board. The carbon track wears. Took resistance readings. The
> two boards gave very different readings.
>
> 7: Car ran a lot better. Still no power. Cleaned air filter and
> replaced fuel filter. A lot better. Replaced the fuel regulator and
> it ran better again.
>
> 8: Few times had trouble starting. Replaced the plugs and cleaned the
> dizzy cap. Started first time every time.
>
> 9: Still running rich and had a hiccup after engine reached operating
> temperature.
> Checked Oxygen sensor and was only outputting 0.3 volts (at op.
> temp). Replaced and `new' O2 sensor had about 0.9 volts. Quite a
> difference. Fixed the mixture problem and the hiccup disappeared.
>
> 9: Test drive and suddenly very erratic behavior. Cleaned all
> connections with CO contact cleaner and re did all earthing points.
> Did not miss a beat until…
>
> 10: Low coolant light came on. Immediately stopped and no coolant at
> all. None on the ground none in the tank hmmm where did it all go?
> Inside the engine!
>
> 11: Head stud corroded through and head nut became loose. Direct path
> for coolant to enter the engine.
>
> 12: Towed home (very humbling). Drained engine and coolant.
> 13: Removed head and spent about 2 days removing broken stud from
> casing. A particularly nasty job. Used a 8mm tube socket, cut a notch
> on the side and TIG welded it onto the 5mm of protruding stud. Then
> applied a lot of heat to the casing with MAP gun and the stud came
> out. All done with engine still in car (see….it can be done!).
>
> 14: Removed and cleaned all the valves and ports. Replaced head
> gaskets and O rings
>
> 15: Adjusted valves.
>
> 16: Flushed engine with 50:50 mix of kerosene and cheap engine oil
> for 60 secounds run time.
> 17: Flushed cooling system using half a cup of phosphate free
> dishwasher powder (mixed with water of course).
> 17: Flushed engine with cheap oil for 5 minutes run time.
> 18: Replaced oil filter and added cheap oil. Ran for about 250 kms.
> 19: Added oil cooler and remotely mounted filter in side engine bay.
> This old girl (330,000kms) runs hot (we have had very hot weather as
> well). And the oil cooler certainly helps.
> 20: 14 full days work and two cases of beer…
> 21: The `tool box' Syncro is purring along like new!
>
> And thanks to Rick who gave up a few days of his holiday to
> help...mind you working on a Syncro is better than a holiday :-)
>
> Regards to all
>
> Peter
>
Peter,

you have undertaken all that frustration, diagnosis and work and only
consumed TWO cases of beer.

You are indeed a remarkable man! :-)


Good to hear the bus is running again.
I assume the Subi conversion has progressed a little as a result?

Thanks for showing us about the forests (etc) of your beautiful part
of the country.

Andy
Ceduna.
Dear Peter,
I'd like to also echo the appreciation that everyone is showing for documenting and sharing your "tool box" machinations.Its a great feeling to persevere, suffer frustration but finally win through.
In case anyone is only half way through the process and contemplating selling (and I suspect we have all been there) I thought these posting from the current U.S. Vanagon site might help you through.
Cheers
Roger

Re: Leaving Syncro Group

Posted by: "TJ Ferreira" thomasferreira@yahoo.com   thomasferreira

Fri Feb 13, 2009 2:12 pm (PST)

I sold my Syncro June 08 and have yet left the group. Just can't
bring myself to do it. <grin>

I guess I am holding onto the thought that one day, when better able
to afford, getting another Syncro.

I must say I teared up a bit when I sold mine. Figuring I would never
be able to get one again. I grew attached to it. I have my aircooled
harem keeping me happy for now but I really miss having the Syncro for
long road camping trips and also, the 4x4 for up where I live. We had
4 inches of the white stuff this AM and Syncro would sure be happy in
this kind of weather. My 2001 beetle don't like it much. 8-)

Best of fortune to you.

tj

--- In Syncro@yahoogroups. com, "enloe5" <jenloe@...> wrote:
>
> It's been great 8 years, and I've learned more about just about
> everything as a part of the group. But the '87 Vanagon Syncro has
> been sold - although I'm not happy. Only thing that convinced me was
> 1) job outside of town reduced my time to fettle; and 2) Ohio seam rust.
>
> Things I've learned about:
>
> 1) Viscous couplings, and non-Newtonian fluids (although I knew what
> they were, just not how they were used)
> 2) Keep the factory settings: they spent a lot of time coming up with
> them (Dr. Woitek, thank you)
> 3) Really cool old man EMU shocks from Down Under
> 4) It's handy to have a spouse with small hands when you're hooking
> the solenoid back up on the starter motor
> 5) It's ALWAYS an adventure in a Vanagon - even on Christmas Eve in
> Louisiana and in a Subway in New Jersey with pay
toilets:-)
> 6) Vanagon people are good people
> 7) Sometimes Vanagon Syndrome can be cured by unhooking the O2 sensor
>
> Ciao - I'll miss this a lot. . . but time to move on."
>


--- On Fri, 13/2/09, Ken <unclekenz@yahoo.com> wrote:

From: Ken <unclekenz@yahoo.com>
Subject: [Syncro_T3_Australia] Re: 'Tool Box' Syncro
To: Syncro_T3_Australia@yahoogroups.com
Received: Friday, 13 February, 2009, 8:18 PM


Gday Peter,

Brilliant post, I reckon your dedication, persistance, enthusiasm and
ingenuity well and truly shows through here with this project, I suspect
many of the rest of us Oz syncro list members are indeed envious of your
abilities, in particular your inspired doggedness at problem solving.

Great stuff Dr. Syncro.

Cheers.

Ken

--- In Syncro_T3_Australia @yahoogroups. com, "Peter" <kestel.p@.. .>
wrote:
>
> `Tool Box' Syncro ?
>
> This is the affectionate name given to my lastest 2.1 liter 1989
> digifant Syncro, simply because it is always full of tools…
>
> This is the van I bought on the day of the Shallow Xing trip. So much
> has happened or has been done to this Syncro and I have learnt a lot
> about how the digifant runs.
>
> I have attempted to put it all down in writing since all of us can
> learn a lot about fault finding and how to fix it scenarios.
>
> In chronological order:
>
> 1: Handed over the cash. It was running on LPG. Previous owner said
> that he never ran it on petrol. The petrol tank was empty. I drove
> away (on LPG) with my new car.
>
> 2: Filled her up with petrol. Would not run on petrol at all.
Hmmm…
> think I suspected that would be the case.
>
> 3: I now have a spare engine from my Subaru transplant operation in
> my camper Syncro. Lots of spares and a great opportunity to find out
> what was wrong with the tool box Syncro.
>
> 4: Replaced the injectors. Van started on petrol. No power, rich
> mixture. Stalled and generally was quite sick.
>
> 5: Removed air flow sensor. The vane was bent and seized rock solid
> (probably having been blown up by a gas backfire (from previous owner
> always starting on LPG).
>
> 6: Replaced air flow sensor although I retained the air flow sensor
> circuit board. The carbon track wears. Took resistance readings. The
> two boards gave very different readings.
>
> 7: Car ran a lot better. Still no power. Cleaned air filter and
> replaced fuel filter. A lot better. Replaced the fuel regulator and
> it ran better again.
>
> 8: Few times had trouble starting. Replaced the plugs and cleaned the
> dizzy cap. Started first time every time.
>
> 9: Still running rich and had a hiccup after engine reached operating
> temperature.
> Checked Oxygen sensor and was only outputting 0.3 volts (at op.
> temp). Replaced and `new' O2 sensor had about 0.9 volts. Quite a
> difference. Fixed the mixture problem and the hiccup disappeared.
>
> 9: Test drive and suddenly very erratic behavior. Cleaned all
> connections with CO contact cleaner and re did all earthing points.
> Did not miss a beat until…
>
> 10: Low coolant light came on. Immediately stopped and no coolant at
> all. None on the ground none in the tank hmmm where did it all go?
> Inside the engine!
>
> 11: Head stud corroded through and head nut became loose. Direct path
> for coolant to enter the engine.
>
> 12: Towed home (very humbling). Drained engine and coolant.
> 13: Removed head and spent about 2 days removing broken stud from
> casing. A particularly nasty job. Used a 8mm tube socket, cut a notch
> on the side and TIG welded it onto the 5mm of protruding stud. Then
> applied a lot of heat to the casing with MAP gun and the stud came
> out. All done with engine still in car (see….it can be done!).
>
> 14: Removed and cleaned all the valves and ports. Replaced head
> gaskets and O rings
>
> 15: Adjusted valves.
>
> 16: Flushed engine with 50:50 mix of kerosene and cheap engine oil
> for 60 secounds run time.
> 17: Flushed cooling system using half a cup of phosphate free
> dishwasher powder (mixed with water of course).
> 17: Flushed engine with cheap oil for 5 minutes run time.
> 18: Replaced oil filter and added cheap oil. Ran for about 250 kms.
> 19: Added oil cooler and remotely mounted filter in side engine bay.
> This old girl (330,000kms) runs hot (we have had very hot weather as
> well). And the oil cooler certainly helps.
> 20: 14 full days work and two cases of beer…
> 21: The `tool box' Syncro is purring along like new!
>
> And thanks to Rick who gave up a few days of his holiday to
> help...mind you working on a Syncro is better than a holiday :-)
>
> Regards to all
>
> Peter
>



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