Heat Exchangers

[mrbodly]

Hi All

I have no heat in the cab, so am going to have a look at the heating system. I've attached pics of the exchangers, do they look past it?
I'm assuming someone has disconnected them because they were faulty, possibly fumes in the cab.

I wondered if there was any way of repairing them?

Cheapest replacements I can find are £200 each from Just Kampers.

Cheers
Myles

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[sarran1955]

Hello,

Seen worse..

The worst bit is the dismantling..

Not much fun under the vehicle..

Still.. assume that every nut is so rusted, the socket will not hold...

The RHS exhaust to turbine support bolt will be a nightmare..

Fit new exhaust nuts and bolts throughout...NOT Nylok..

Once off.. wire brush off all the rust, you can build up the rusty tinware with exhaust repair gum..

Paint the exhaust with woodstove black..the exchangers.. Hammerite (or similar)

.. the connection between the heater wires (from the front) and the exchangers will be shot.. cheap to replace..

Make sure that the heater control wires work when you move the dash lever..

If so blow through the tubes with compressed air.. and get some preserving oil in them..

If they are broken.. you can wire the exchangers open to give heat..

The nasty smells etc are due to filth on the exchangers.. probably a filthy engine too..

VW Aircooled = clean engine = happy engine..

Clean up the stud threads with an 8mm die..

Part way through this shows you what I mean..

http://www.youtube.com/watch?v=wGvhxtW8HN0" onclick="window.open(this.href);return false;

Get yourself a curvy 11 mm and 13 mm Geodore ring spanner...


Make sure you get the right exhaust gaskets..

20 minute job..

Oh.. and 'reassembly is the reverse of the above procedure'..

Have fun.. work safely.. gloves and glasses please..

If it all works.. be ready for an incredible amount of 'carp' blown out of the vents..

Cordialement,

[mrbodly]

Thanks for the response. The threaded studs on the silencer are rusted solid, there's no way the nuts will come off.
Is it possible to remove the silencer and exchangers as one complete unit?

[mrbodly]

Also, is it likely that the exhaust inside the exchangers is still intact or do these have attendance to fail and leak exhaust fumes?

Cheers

[sarran1955]

Thanks for the response. The threaded studs on the silencer are rusted solid, there's no way the nuts will come off.

.....told you...

Nut splitter.... airsaw (my preferred).. cold chisel and knuckles

Is it possible to remove the silencer and exchangers as one complete unit?

No re read the above..

The exhaust tubes them selves are made of 'Eternium super alloy' will outlast you..

Cordialement..

[johnfevs]

This is my next job when I get some free time. I'm going to take them of and see if I can repair them. I know the near side one has 2 small holes on the pipe that drops down to the heat exchanger which I hoping to get welded up.

Keep me posted with your progress

[johnfevs]

Where is the best place to buy new heat exchangers. Just Kampers and Brickwerks sell them at arount £200 each, but will 1 be better or worse than the other???

Anyone out there bought any heat exhangers recently.

Cheers

[R0B]

Given the choice.Brickwerks every time.

[The Bobdogs]

some on ebay at the moment...

[johnfevs]

After looking at the ones on ebay (£70 each) and weighing up the pro's and cons of 2nd hand, I have bought 2 brand new ones from Brickwerks, ordered and delivered in 24 hours, great service. Now I need to find some time to get underneath and try and get the old ones off and the new ones fitted. Hopefully get some time to myself over xmas.

[johnfevs]

I'm going to change the heat exchangers this weekend. Hopefully I can get the old ones off and new ones on without too many problems. I'm also hoping to make up some new tins that mount off the heat exchangers and a new tin that mounts above the exhaust. I will try and make some patterns of the new tins.

[mrbodly]

I discovered the main duct running from the back to the front of my van was blocked. The cardboard lining had collapsed completely blocking the airflow. I replaced both pieces of duct with insulated ducting and now have heat in the cab. I still need to patch up the exchangers though.

[johnfevs]

Just removed both heat exchangers and the exhaust. Glad I bought new ones as the old ones are completely shot.

Cleaned up exhausted and going to respray with heat resistant paint.

Now to refit the new exchangers. I will list some photos later

[johnfevs]

Quite time consuming. Fitted the exchangers with no problems. Made a new piece of tin that sits above the exhaust and refitted.

Thought I'd tidy up and call it a day, then the problems started. I couldn't get the engine started. It was trying to turn over but not doing much else. Could this be because I do not have the exhaust fitted?? Lack of compression or something to do with the starter motor. Any ideas anyone.

I will refit the exhaust tomorrow and try again. Otherwise I will have to get the wife and kids to give me a push to jump start.

[BOXY]

I've run motorbike engines with the exhaust off so it shouldn't stop the engine from starting. If the engine is turning over you might want to check you haven't pulled off a fuel hose while you've been working. The fuel pump isn't a million miles away from the heater pod risers. If it's not turning over, check the spade connector on the starter solenoid. It's easy to knock this off when under the van.