On the road at last !

[Roving Rich]

Well I'm finally on the road !
There is still a long list of jobs to do, but now its a rolling restoration.



I've been having fun in the snow, but the diff locks still aren't working
I've played with most of the joints in the pipes, to no avail.
They took some unearthing, but had the dash out to unseize the heater fan.



I suspect a lack of vacuum. The brake pedal seems quite heavy, but effective ? Not got anything to compare it too. Can I pay a visit, kick tyres and get some opinions from some of you local guys ?

I've traced the pipework back to the engine bay. Where I expected it to go into the inlet manifold, but no that would be too easy !
It disappears into some box of tricks at the back of the engine bay. The "EGR" exhaust gas recirculation gizmo ?
Its TDi territory, so not much help from the manuals.

Ultimately the plan is to turn into a family camper and head off into deepest Europe for some adventures.
Got some interior bits, but need a Pop top for the kids. I was quite taken with the vast Viking one, but it is a bit excessive. Are they all much of a muchness ?

Well guess I better start the list....
1. Rust - sort the seams out.
2. Spare tyre on a rim
3. Interior. Oooh another can of worms, Gas...rock n roll beds...
4.Windows - bodge up panel van steel or put in new frames ? not sure how they work
5, Cab steps - Weld em up solid without the drain hole moisture traps.
6. Poptop
7. GO SOMEWHERE ON HOLIDAY ! I'll be needing some more inspiration by that point I'm sure
8. Tinker with TDi, try to sort out hunting, oil leaks
9. Move throttle sensor to the front of the van and run the wires back.
10. More camper bits me finks
11. Shotblast and underseal, Eeek does that mean a stripdown or can it be done intact ?

Sidetrack...I found an old thread on Volkszone when searching for Tdi info. Turned out to be about my van ! And an old classified ad for it.
Was interesting to read previous queries and see what had been bodged earlier.
Haven't found much info on Tdi conversions yet. The Links off the Wiki here are largely dead.

Well its snowing heavily here. Just had a phonecall to blag a lift to work in the morning form some lesser non syncro owner

Cheers
Rich

[jed the spread]

Is that one of those rare, 7 ever made RHD Velle's?

jed

[sonic23]

Good work that man.
And what great weather to finally be rolling in too (though no snow here on the Bristol Channel)

Rich

[KarlT]

Just out of interest, is there a list of production figures somewhere, for all (including 2WD) the different models?

[Roving Rich]

Yes Jed - £10ks worth

No sadly not, its a rusty panel van convert.

Well has to be said its awesome in the snow and ice. I dunno if you lot take it for granted, but we're blown away at how sure footed it is.
I hauled a stuck passat estate, followed by an audi A8 estate up a hill this morning, from a standing start on ice we couldn't stand up on.
What a vehicle. I can see why they are so popular in Scandinavia

Cheers
Rich

[lhd]

Re: the lack of vacuum, have you checked the vacuum pump is working ok?

It should give a real good tug on your thumb when placed over the pump, which should almost leave a mark.

If the pump is not working as it should, it would cause the brake pedal to be stiff and could be the problem with the diflocks too.
Remove the pipe from the vacuum pump carefully as they can break quite easily, new ones can be sourced quite easy if it does break.

Also when you undo the pipe that goes to the vacuump pump you should hear a whoosh of air, If so it means the pipework is holding vacuum, if not and the pump is ok, you know the problem is downwind of the pump.

Has it always been like this or got worse with the cold weather?
Rob.

[Roving Rich]

Thanks Rob.
As far as I'm aware I don't have a vacuum pump ?
Pump implying that it is driven from somewhere, off a belt or or cog.
I have only ever seen brake servos run from the inlet manifold vacuum. Tracing the pipework back it goes to a strange box of tricks at the back of the Tdi engine. It looks like it has a one way valve in it, but I cannot tell where it would get a vacuum from.
The front locker never worked, but i have replaced the front diff and actuator, and it all moves as it should.
The rear worked a few months ago before I took it apart to do the front diff and drive shafts.

Cheers
Rich

[..lee..]

td / tdi vac pump looks like this.

http://www.ebay.co.uk/itm/Galaxy-MK1-95 ... 0799511982" onclick="window.open(this.href);return false;

[footstuck]

It is situated on the same side of the engine as the injection pump,
And is above the oil filter housing the back of the block.
There are non return valves that blockup or get sticky.
Note which way they are installed, I remove and clean mine
With WD and a gentle blow of compressed air.
I'm also betting your diff locks will operate once you've sorted out the
Lack of vac.
Well done getting mobile
There is a non return valve in the top plate of the Vac pump
3x6mm bolts secure it from memory.
If it is not serviceable, this valve is available from VW and comes with the top plate complete

[Roving Rich]

Thanks guys - I'll have look next when I get a chance.
i'ts done a sterling job of hauling a trailer full of over a ton logs 100 miles.
I'm lovin it

Cheers
Rich

[Roving Rich]

Spot on thanks guys - traced it back and compared notes with Lee's link and found the pump.
Disconnected it and blew through the one way valve. Seems to work fine ?
There does appear to be suction. Enough stick my thumb to the end of the pipe, and leave a raised bump. There was also a good hiss as the hose came off ?
Seems to be fine ??
I wonder about the brake servo now ? Its those solid plastic pipes which seem to be impossible to do anything with ? I wonder if I can warm em up to remove them ?

Cheers
Rich

[mynameisstuart]

hi, i have the same issue. i need a vacuum pump cap. any ideas where to buy one from. i have a '85 1.6 diesel non turbo. or how can i job it for a while. i was thinking quick steel epoxy putty. please help, this is the last big problem i have.

[Roving Rich]

So I'm still having diff lock/vacuum troubles.
I was hoping to get the diff locks working and come up to Shipston for a play, but it is looking increasingly unlikely

So far
Checked and double checked the one way valve by the reservoir. WD40'd it and it seems to function fine.
Replaced small connector pipe between vacuum line and one way valve.
Located vacuum pump, removed and replaced braded rubber pipe between rigid pump pipe and main servo vacuum pipe.
Seems to be lots of suction. Enough to fold the replacement pipe flat, so re fitted original.
Checked that the lock lights are working by bridging the plugs the diffs.
Operated rear diff lock with a screwdriver, moves freely in and out, and locks with wheel rotation.
Disconnected all pipes and blown them through with the airline.
Plugged the front diff pipes at the actuator.
Disconnected the servo line at the T piece by the reservoir and plugged it. Seems be lots of vacuum here, but not a great deal on the T
Connected the rear diff actuator directly to the vacuum line (by pass switch)

Still no Joy.

~Ordered some 4mm nylon hydrolic pipe and silicon vacuum hose to join it with. I'm not atall sure of the rubber hose I'm using.
So the next plan is to by pass the line to the switches, and see if the fault is there ? It means I can also run a line directly to each actuator and try to operate it.

I have spent alot of time getting nowhere with this. I still have no idea exactly where the problem lies.

Rich

[v-lux]

Worth checking that there are no holes or tears in the little red boot on the plunger on the actuator.

(if you knock out the roll pin, undo the two bolt holding it to the mount and remove the actuator you should see the little boot i mean)
If these are damaged in any way they will affect the operation as they are part of the vacuum system.

Also, make sure that the roll pins are not poking out of the shaft at all, can be easily overlooked and will stop it engaging.

Clutching at straws, but you never know.......

[Roving Rich]

Well my Syncro is getting well used.
I seem to have done more miles towing something than not ?
So a few log runs, towing caravan, weighing in my mums car on the trailer and towing a friends car to the garage.
Its trundling along nicely. I even have a working rear diff lock, which got used in anger hauling the logs up a wet grassy hill.
Oh done a couple a little green lanes too.
And the wife managed to get 85 out of it ! I was sat in the back, and thought it was swaying around a bit, crawled forward to discover we were tanking along !

I still have lots to do. Fiona has been ill with Viral Pneumonia, so I had time off work and the weeks holiday I'd booked off got used up looking after the kids and her
Very frustrating looking at it out the window, and being unable to get on.
Top of the list currently is welding. I want to cut out the rust near the jacking point and make it sound before I cut a hole in the roof and fit the poptop.







Oh and slept my first night in it. Or not, got a couple of hours kip with the dog and 5 year old daughter chattering away half the night, and she insisted we have a light on...Still was nice to Christen it.

My friend is looking at an awesome Landcruiser Camper, so there might be some adventures ahead

Cheers
Rich