Diesel Vanagon Battery and Charging System

Ok, I know I haven't produced any new blog posts all summer.  Not that Westly and I haven't been spending a lot of time together though - quite the contrary.  It's just that life as I knew it took a rather dramatic turn when Van Spouse and I separated (for reasons beyond the scope of this blog).  Following a tearful goodbye, Westly and I headed off under a stunning sunset that seemed especially suited for the occasion.

The intrepid van became my full-time home for a time, inhabiting rest areas and parking garages until I was offered a comfortable basement room in the home of some very kind and gracious friends. Westly no longer has quiet, secure off street parking and was even egged a few nights ago (really - people still do that??) but he's adapting well.

One of the worst aspects of the situation is that Van Kid is no longer "allowed" to go camping with me.  Hopefully we can work that out in the future but camping without him is kind of dull and now that school has started weekends are the only time I see him, so outings have been greatly curtailed.  One of the more memorable though was a day hike to Talapus and Olallie lakes.  Van Kid traversed the entire eight miles with no complaining, carrying his own pack.  Way to go Kid!

Van Kid at Talapus Lake
Too cold to swim but we had fun watching crayfish along the shore

Taking a break along the trail
Photo by Van Kid
Gawd I'm looking old!

So what else did we do all summer?  My friend Redwood and I took a trip to Seven Bays on Lake Roosevelt in North Eastern Washington.  Redwood's dad lives there in a unusual combination  of house and airplane hanger.  With the temperature hovering around 100 degrees F, we did a lot of swimming and exploring the lake in a rented skiff.  This is a large reservoir lake, about 150 miles long with 600 miles of shoreline, so we didn't get to see it all (understatement alert!).  You can rent a really nice houseboat here for $1,000 a day or so depending on the size and season.  The largest boat sleeps 13 (but with only 10 pillows so somebody will have to bring their own) and sports a hot tub.  Our skiff didn't have a hot tub, but did feature a lovely swirling pool of bilge water.

Redwood's dad - the Pilot Poet
Physically grounded but mentally soaring

View from inside the cool dark hanger to 100 deg f bright sunshine outside
That's one serious garage door!
The grassy area beyond is a runway

Piloting the skiff on Franklin D. Roosevelt Lake

Along the way, we stopped at the Reptile Zoo near Monroe, WA.  At this serpentarium (real word - I googled it) we were awe-struck beholding such sights as a two-headed turtle (they claim the heads have individual personalities), albino alligator (looking forlorn in it's concrete tub), the Worlds 10 Deadliest Snakes(!), a Goliath Bird-eater Tarantula (name not so representative of the actual product) and my favorite, Blaberus Giganteus - the giant Brazilian Cockroach with prime specimens approaching 3.5 inches long (sometimes kept as pets & tethered by tiny leashes).

By the way, I was reading recently that incorporating too many parenthetical statements was a sign of poor writing.  Well ok...guilty!

Green Mamba- bite 90% fatal, can slither up to 15 mph (yikes!)
Or maybe it was the African Bush Viper, but the Mamba is just way more interesting

Other shorter trips took us hiking, fishing and sightseeing but plans to journey to Yellowstone and make more campouts with the WetWesties had to be postponed for a future summer.

Westly performed flawlessly, if ponderously most of the summer except for a period where he petulantly refused to start, particularly after sitting alone all night.  Some mornings he would start right up with vim and vigor, other mornings just an abject clicking or worse - no response at all.

The diesel engine is an utter power hog during starting.  First the glow plug circuit is activated - essentially four heating elements that glow red hot to get the combustion party started.  Then, the starter motor which must overcome 22.5:1 compression (some 2 to 3 times that of a standard gas engine) to turn the engine over.  Once it's going though, because a diesel has no coil or spark plugs (and in one of this vintage, no computerized anything) it has virtually no electrical load - just a small fuel solenoid that could operate on a 9-volt battery if necessary.  In fact, here is a keen trick I learned.  You can wire up a 9-volt battery (we used to call them transistor radio batteries back in the day) to a pigtail that connects to ground and the solenoid wire.  Then if the van battery it totally dead, you can attach this small battery to open the fuel solenoid and push start the van.

Portable jumper battery under the back seat, wired through an Anderson Power Pole connector
directly to the starter and ground.  Makes jump-starting sooo much easier and quickly
detaches for other uses

Anyway, the voltmeter during the less active starts would show only 8 or 9 volts, not nearly enough to accomplish the formidable task before it.  It would jump start easily, or after having a battery charger on for a short time.  And it would push start readily so in addition to the portable jumper battery, I took to parking on hills whenever possible (not too difficult around Seattle) so I could coast a few feet and pop the clutch in 1st gear.  Works, but I imagine this procedure is a little taxing on the equipment.  I cleaned and tightened the battery cables to the engine block, the starter and the braided ground strap between the transaxle and the frame.  This helped, but not enough.

Interstate MT-41
650 cold cranking amps
This is the battery you want for the Vanagon diesel

Even though the battery was not quite three years old, I suspected a weak cell or two and brought it to the local Interstate Battery Center for testing.  They pronounced it adequate.  I countered that it certainly would be with a gas engine, but was sorely lacking in getting the diesel motivated.  After some deliberation, they agreed to replace it.  The battery has a 72 month warranty but reading the fine print reveals that if installed in a diesel engine vehicle, the warranty period is halved.  With the pro-rated warranty I ended up paying $60 instead of the original price of $135.

This effectively solved the starting problem but then a couple of months later the charge indicator light stubbornly refused to go out.  The voltmeter showed no charging action at all and the drive belt was tight so I called my favorite local parts store and ordered an alternator which arrived within the hour.  I had trouble removing the alternator from the mounting bracket, so unbolted the entire assembly and brought it in.  The helpful folk at Auto Sports Imports in Seatac, WA got them separated and swapped the pulley from the core to the new alternator for me at no additional cost.  I love you guys - if you had a website, I would include a link to it here!

Rear view of the Bosch AL33X alternator with "W' terminal
that sends the signal to the tachometer

Back home, I installed the alternator and bracket along with a new belt.  Success - now charging at 13.8 volts!  I noticed that a little over 5,000 miles had accumulated since the last full service so Westly also received an oil and filter change, air filter cleaning, new fuel filter, tire rotation and heaps of positive affirmation.

On another day I replaced the bushing that supports the sliding door handle as mine was missing, allowing water and dust in and making the outside handle all floppy feeling.  The little knob that locks and unlocks the door from the inside had fallen off and gotten lost on some bumpy dirt road so I made a replacement from an extra front door lock knob I had scavenged from a parts van.  While the inside door panel was off I tightened and lubed the lock and connections.

Now Westly's charging system, engine, tires, and doors are all operating smoothly.

Hoping my life will smooth out as well...

Vanagon Transaxle Oil Change & More

Westly's transaxle has a leak. A very occasional drop on the driveway and when I'm crawling around underneath (which I do periodically to check things out) I wipe the shiny spot off the bottom of the case. It's not the flange seals as I replaced those when renewing the CV joints. It's coming from somewhere deeper -  maybe the seal/o-ring on the adjusting ring - but lacking a puller to remove that part, I just roll with it. 

But after enough drips, I knew the oil level had to be getting a little low and there was no record of when the oil was last changed. Ideally, it should be done every couple of years, so one spring morning when the dew adorned the daffodils like sparkling baubles, I set about the task.

The fill plug can be difficult to remove. It's a good idea to make sure you can break it loose before draining the oil - otherwise you would be stuck in your driveway, friends driveway, parts store parking lot, etc until you are able to extract it and refill the box. As gear oil is highly viscous, I let it drain for a day or so, raising the front of the van to coax it all out. The DZ transaxle capacity is a little over four quarts. Only around three drained out. Guess it had been leaking a long time! The oil had a few tiny yellow metal flakes suspended in it, the magnetic rod on the drain plug was mostly clean.

I put in four quarts of Royal Purple Gear Max Synthetic 75W90 oil. This wonder of modern technology is API rated at GL-4 and GL-5, is non-corrosive to "soft yellow metals" which are evidently found in abundance inside the transaxle, and possesses "proprietary Synerlec additive technology". This is some way pricey gear oil, but I figured a transmission rebuild isn't cheap, so why not be protected by the best I could get? Subsequent research online has me thinking that most any gear oil with the proper rating would suffice - the key is to change it on a regular schedule.

Synthetic oil does pour much more readily than honey-like dino oil (which requires a pump that usually breaks when you're about half-way through filling). I set up a funnel with a clear pvc tube on the end to poke into the fill hole and the bottles dumped quickly. With the van level, you keep filling until oil dribbles back out of the fill plug hole, then close it up.

Fill plug on the left.
Drain plug on the right with a magnetic rod to keep
any metal bits from circulating in the oil.

There's not enough room to get a 17mm allen wrench on the fill plug.
This adapter tool makes getting the plugs
in and out easy.  You could also use a double-nutted
17mm head bolt and wrench.

Removing the right rear wheel allows better
access to the fill plug.

The fill plug is on the right rear of the box.
The white blobs next to it are lithium grease on the shift rod coupling.

The bottle just fits in the funnel.  Avoid contaminating your new oil by
washing loose dirt and debris away from the area ahead of time.

Prior to the oil change, I would hear and feel a little "snick" when shifting from 1st to 2nd gear (particularly after having not driven for a few hours) unless I did so very slowly and deliberately.  I don't know if it was because the oil level had been low before, or it was due to switching to synthetic oil, or maybe the "proprietary Synerlec additive technology", but after the change that "snick" is history.  

Air Filter

When Westly's engine was replaced, the original air filter box was discarded and a funky ABS drain pipe fitting was constructed with a K&N filter on the end. It attaches to the intake manifold with a flexible rubber "hub-less" connector. It has apparently performed it's task well for 30,000 miles or so, but over time heat from the nearby exhaust manifold caused the ABS to shrink and crack. The best part about this is that all the parts are readily available at most any hardware or home improvement store. I glued up a new unit with an additional piece to situate the filter in a more protected area - it formerly hung down low beside the engine where it was subject to all manner of road grime. After washing and re-oiling the filter it all went back in place with the addition of a support loop of heavy gauge wire to keep it from bouncing around so much.  

Westly's custom low restriction air intake system

I've seen online where some Vanagon owners with non-stock engines have adapted the air filter box from from a '90s Chrysler mini-van.  The filters are easy to find, inexpensive and it all fits very well in the space to the left of the engine.  And you can attach the original snorkel hose that runs up to the left side air scoop (left over from when the Vanagon was air-cooled) so the air intake is situated high, out of the trail of dust and water spray kicked up under the van. Next time I'm at the Pick and Pull, I'll check one out.  

Vacuum Pump

Vehicles use vacuum for various accessories such as cruise control, heating & A/C controls, door locks.  The Vanagon's primary use of vacuum is the power brake booster.  Diesel engines do not produce vacuum as gas engines do (during the combustion process), instead they have a mechanically driven vacuum pump.  While doing some poking around Westly's engine I noticed the hose connected to his vacuum pump was cracked. Bearing in mind that plastics become increasingly brittle with age, I slit the hose where it attached to the pump fitting and pulled. The fitting brashly responded to my careful preparations by separating into two pieces, shamelessly exposing it's inner parts. After an unsuccessfully attempt at gluing, I made a plea to the online Vanagon community for help.  

The broken fitting.
(white with a little red thing poking up the middle)

The new fitting, hose, and check valve in place

It seemed the preferred method of repair was to remove the cover and the original fitting (which was pressed in), cut threads into the hole and insert a brass hose barb. The threads of the barb must be shortened and ground flush so they don't interfere with the pump vanes which spin directly below the cover. I accomplished all this quite handily, and put it back together with new hose and a check valve from a BMW (keeps some vacuum stored in the hose and booster so you get a couple of assisted brake applications with the engine off).  It works perfectly and should last a good long time.

Alternator Bracket

All relationships come with some baggage. When Westly rolled into my life, he had this un-orthodox alternator bracket cobbled together from an old Ford part and some scrap metal. The drive belt was impossible to fully tighten which led to incessant squealing. This was highly embarrassing - I just couldn't take him anywhere.

M-I-C-K-E-Y   M-O-U-S-E

Because of the engine cover directly above, and the battery directly to the right, the space allotted for a bracket was very limited. I had an idea of what the ideal bracket should look like, and searched around wrecking yards but came up with nothing. I tried to contact a friend who has metal fabricating skills and equipment, but he pretended he never got my message so I knew I was on my own.  

Looking around in my pile of Stuff That Is Pretty Much Useless But Too Good To Toss, I came upon a bracket left over from when an old garage door opener motor failed and it was cheaper to buy a whole new opener package than just replace the motor. This is the bracket that attaches the chain drive mechanism to the door. It's fairly thick steel, though not all that hard. The curve looked just right, and I figured it was worth a try so cut out a notch to clear a protrusion on the alternator body, and a slot for adjusting belt tension. The lower mounting hole needed to be opened up slightly for the bolt to fit.

Original door opener bracket below.
Modified bracket above.

The bracket in place and looking
just slightly less M-I-C-K-E-Y  M-O-U-S-E.

I put it all back together, and determined a shorter belt would be needed.  With that in hand, it all fell into place and has performed well now for 6,000 miles.  I always check it over carefully whenever the engine cover is off.

Mud Flap Mend
Vanagons with the Westfalia conversion are equipped with a single stout mud flap behind the left front tire.  It's purpose is to stop debris kicked up by the tire from damaging the propane tank that hangs under the van directly behind it. I noticed Westly's flap was starting to tear and had some vague idea about reinforcing it before it separated, but didn't get around to it. Then, on a particularly rough road near the Wild Horse Wind Farm, it let go. Luckily, we were turning around at the time because the road was quickly becoming impassable, and Van Brother, who was outside directing me so I wouldn't get stuck in a ditch, found the detached part. I later used some galvanized straps and a handful of brass bolts to re-unite the two pieces.

Yeah, it's ugly but it will do until I can get
a full set of mud-flaps from Van Cafe

I had inquired about getting "Slopoke" for Westly's license plate, but found it was not available. We discovered it on this supercharged Saleen Mustang at a Father's Day car show. In fact, in Washington state every variation of the word 'slow' is already in use, likely all on vehicles with exponentially greater horsepower than Westly. Such irony. 

Another intriguing ride at the show, the 1958 BMW Isetta. The 13 horsepower single cylinder motorcycle engine propelled the car via chain drive to a top speed of 53 miles per hour.  The only way into the car is through the front door which includes the wind screen, the instrument panel (speedometer, light switch and ignition key), and the steering wheel (the shaft is hinged so it moves aside as the door opens).  This one had two wheels in the rear with a narrow track so no differential is needed.  Earlier models had only one rear wheel and were subject to tipping.  I assume the third brake light is original, as the rest of the car seemed so.  Looking at the size of the license plate relative to the body of the car gives an idea of the proportions of this micro-machine - like a Smart Car ancestor.

I have a foggy memory of my cousins and me playing with a toy model of this car while visiting my grandmother in Santa Ana.

Blackstone Labs Oil Analysis

Westly's 1.9 liter normally aspirated (non-turbo) diesel was installed in 1992, but I don't know if the engine was new, used or overhauled at the time. Nor do I know exactly how many miles have been driven since the installation as the odometer was inoperable much of the time. By analyzing maintenance receipts and taking into consideration information from the Previous Owner, I figure in the neighborhood of 30,000 miles is close.  I've not performed a compression test, but the engine seems tight, feels strong, runs as smooth as a diesel can be expected to, has good oil pressure and doesn't leak or burn oil - I never have to add any extra between oil changes.  

I had previously switched to synthetic motor oil after observing high oil temperatures at freeway speeds as synthetic oil will sustain higher operating temperatures than dino oil without breaking down.  Now 5,000 miles had passed since the move to Mobil 1 5W40 synthetic "Protection For Hard-Working Diesel Trucks" oil and I was curious about how it was holding up.   

Knowing that an oil analysis would provide useful information about the condition of the oil and engine, I requested a test kit from Blackstone Laboratories.  

The test kit consists of a small (3.5 oz) plastic bottle, a larger bottle, a zip-lock bag and some absorbent materiel.  You fill the small bottle with a sample of oil (they recommend if you are changing your oil at the time, try to take it from the middle of the dump rather than the first or last oil out).  Complete a form with information about the engine, mileage, miles the oil was used, how much oil was added between changes and so on and put it in the larger bottle along with the sample (which is in the zip-lock bag with the absorbent materiel).  Seal it tightly!  The postage to mail it to Fort Wayne, Indiana was $2.29. The cost of the analysis was $25, plus $10 more for a "TBN" which measures the additives available (useful if you want to extend mileage between oil changes).  If you have a fleet of vehicles, you can prepay for multiples of samples which reduces the per sample cost.  

Sample Test Kit - free from Blackstone

I collected the sample, mailed it off and in about a week I received an e-mail with an attached .pdf of the report.   They also mailed a hard copy along with a sheet explaining how to interpret the report, and a couple more test kits.  

The first report came back identifying my van as an air-cooled gas engine; likely the default for a 1982 Vanagon.  I contacted Blackstone and we got it straightened out.  A new report came soon after. They keep track of each vehicle and report and the previous values will show on a later report for comparison.  

The report - click to enlarge

They check the working viscosity, flash point, test for metals which come from internal wear and contaminants which could indicate problems such as a leaking head gasket, cracked head or block, or overly rich fuel delivery.

The report and accompanying comments indicate Westly's engine is in very good condition, showing wear that's typical for the mileage of the oil sample, and a "strong TBN" suggesting that the oil change interval could be stretched out to 7,000 miles. I might go with 6,000 miles, which would bring the cost of my synthetic oil change down to what I would spend on a dino change every 3,000 miles. Of course, Blackstone Labs emphatically states that how often you change your oil is up to you, and assumes no responsibility beyond the cost of the analysis in the event of any oil related engine troubles.

As the cost of the analysis is just a little less than the cost of a do-it-yourself synthetic oil change, I don't foresee ordering one with every oil change, but possibly once a year.

Update 06/10/12

Since I posted this, I've been informed by some Vanagon drivers that oil analysis reports are a waste of time. The reason, they say, is that your engine is going to wear out anyway. Why spend  money on a report that confirms it?  If you have a cracked block or leaking head gasket, there are other more expedient ways of finding out (water/oil mixed, exhaust gasses in cooling system, etc.). Are you going to tear down your engine just because a report showed an increase in the elemental components of bearing surfaces? It's just one more thing to worry about!

Valid points, but here's why I would still consider it an important part of regular maintenance. I wasn't concerned about Westly's oil temperature until after installing an oil temp gauge. Once I was aware of the problem, I could do something about it. This first report is my benchmark. Maybe, depending on annual mileage, I'll wait two years to do the next report, but when I do I'll have a comparison. If a future report shows some anomaly, I'll try to discover why - maybe an engine tear down would be in order but maybe not. If all the report shows is the natural progression of wear and tear, then some prediction might be made as to the expected service life of the engine. Without the report's information about additives present in the oil (what they refer to as TBN), I could be changing oil unnecessarily early - a waste of time, money and resources.

Vanagon Windshield Replacement

Driving with a cracked windshield doesn't bother me all that much.  In the state of Washington, a crack is not a ticket-able offense unless it impairs the driver's vision.  Contrary to what the radio commercials tell you, a cracked windshield is not likely to suddenly fall in your lap, shower your loved ones with glass shards, or blow out all over the road.  It doesn't affect the structural integrity of your vehicle - I think that's what all that metal is there for.  It can affect the performance of the airbag in certain types of accidents, so that could be a concern, but no Vanagon's were equipped with airbags.

I did lose a windshield years ago driving a 1974 bay window panel.  I was driving along Badwater Road in Death Valley when a motor home passing in the other direction kicked up a rock about the size of an orange.  I think it may have been lodged between the dual rear wheels and launched out, but I'm not sure.  Anyway it struck at face level on the passenger side (luckily I was driving alone) made a large hole and shattered the entire windshield.  I stopped by the gas station at Furnace Creek, removed all the remaining glass and deposited it into their dumpster.  I was about 300 miles from home. As you might imagine, driving without a windshield on the freeway produces a high degree of wind turbulence inside the van (and an accompanying huge amount of drag). Rummaging around in back, I was surprised to find my full face motorcycle helmet. Wearing this bright red helmet allowed me to drive with my eyes open (preferable to the alternative) although it also made me the subject of some finger pointing accompanied by guffaws. A little rain fell on the return trip, and upon reaching home I was amazed at the diverse collection of bugs crawling about in the back of the bus.

Westly's windshield was cracked and had a couple of "bulls eyes" as well.  The crack , about 27 inches long with a 3 inch branch upwards was a nuisance to passengers as it lay directly in their line of sight.  When freezing weather came, it extended another 12 inches toward the driver side and then I knew it was time to search for a replacement.

New glass is relatively easy to find (comes out of China now), but I checked on Craig's List first and found just what I needed - a windshield from a '90 Vanagon, including the rubber seal for $50.  I hightailed it over to Leschi to take a look.  No cracks or pits, just a little scratch from scraping it on some other parts while wresting it from the loft of a backyard storage shed.  It had the upper tint (my original did not) which seemed horribly blue when the glass was sitting in my shop, but now that's it's been installed, I don't really notice it. The rubber seal was pliable with just a little blue paint on the edge from a careless masking job at some point.  Bonus - it didn't have the chrome plated plastic trim that was common to the older seals which after 30 years is cracked and rusty brown looking.

The "new" glass  (upside down) - the blue tint doesn't
seem that dark now that it's installed

We struck a deal and I made plans to install it with the help of a neighbor who reportedly had some experience with the task.  This turned out to be a very good plan, as he not only knew how to do the job, he also had a large, heated shop into which we could drive the van and close the door.  The van is too tall to fit in my tiny shop, and the weekend forecast was threatening freezing rain and snow.

We removed the wiper arms, cut the old seal and pushed out the cracked glass from the inside. This was fun - scrunch down in the seat, put your feet up on the glass and push!  Rust in the lower corners of the windshield frame can be a big problem, requiring repair before proceding.  I was relieved to see all the supporting frame was in perfect condition.

No rust!

After cleaning the frame, we applied a little KY jelly around the corners ( the most difficult place to seat the seal). Preparing the seal involved pressing it into place around the glass then inserting a polypropylene string  into the groove with a loop of string left at the top.  I was inside with a blunt instrument (so as not to poke through the seal) and worked around the windshield starting at the lower middle, one hand manipulating the seal with the tool, the other hand pulling the string out as the seal slipped into place along the frame. My neighbor was on the outside pushing gently on the glass and giving me all kinds of helpful advice interspersed with dire warnings about the glass cracking if I made one false move. It took about 15 minutes of this to fully seat the windshield.  I later squirted a little polyurethane caulk under the edge of the seal because some water was seeping in - not while parked but while driving in heavy rain.

Windshield successfully installed!

After finishing the installation, I took the opportunity of being in the large heated space to raise the pop-top and waterproof the canvas.  A couple of 14-oz cans of Kiwi Camp Dry sprayed in two coats (had to turn off the heat and open the door for ventilation) seemed to be enough  - we'll see next rainy campout.  I also washed and hand waxed the entire body.


The same week, while perusing Craig's List I found a local Vanagon owner offering a set of four wheels, tires and hubcaps for a very reasonable price.  He had recently purchase a new set of 15" wheels and tires from GoWesty and wanted these out of his garage.  The tires were fairly new with hardly any wear, and most importantly were the correct load capacity for the Vanagon.  These vans are heavy, especially when you add the Westfalia conversion.  Finding 14" tires with a load rating of about 1,600 lbs is not that easy (which is one reason why the 15" or 16" wheel conversion is so popular - many more tire choices).

Someday I'd like to find some 15" wheels like this for Westly
Original equipment on 2000 Mercedes CLK

We met by the Fauntleroy ferry terminal and made the swap - his unwanted wheels and tires for my cash.  The deal included a set of GoWesty hubcaps and valve stem caps with tiny VW emblems on them.  After a half-hour or so of Vanagon talk, we parted happy.

Ready to go - but first, a couple of weeks of freezing weather

A small electric heater kept the inside warm and dry

I do have a cover - but didn't put it on in time 

Ruby's Delivers

I'm a kinesthetic style learner.  I can read detailed instructions and maybe eventually figure them out, but one good picture or better yet, let me watch you do it and I've got it.  Miss Peacock patiently tried teaching me music theory and sight reading, but it didn't take - however, listen to a piece a few times and I can usually play it on keyboard or guitar.  I can figure out by estimated MPG and odometer reading how far a given vehicle should be able to travel before re-fueling, but seeing exactly where the needle is pointing when it runs out really drives it home for me.  My Outback will happily roll on another 100 miles or more after the needle points to E.  Not so for Westly.

The point where Westly's tank runs dry
The thick mark just right of center indicates about 10 gallons used of the 15.9 gallon capacity

After Van Kid and I left the Spring Cruise-In at XXX Root Beer Drive-In in Issaquah, we continued East on I-90 toward Snoqualmie Pass.  I wanted to test Westly's mettle after having done some fine tuning on the injection pump and Van Kid wanted to play in the snow.

Westly, making use of every one of his 68 ponies, was willing to charge up the grade at 60 mph, but I backed off to 55 to keep the oil temperature down to a reasonable 230 degrees f.

We didn't have tire chains, so followed a forest service road before the summit as far as the plow had gone, parked and hiked in a short way.

The end of the road

Van Kid checks out a freshet

Time to hit the road

But first, a snack

After becoming thoroughly chilled (not really having dressed for the snow), we had a snack, then headed west and stopped at  Snoqualmie Falls .  This time of year, a lot of water is going over this 268 ft falls (as opposed to being diverted for hydroelectric purposes). The trail down to the base of the falls was closed for repairs, but we had a grand view of the falls from the observation deck.  From the falls, we continued on Hwy 202 toward Fall City, then cut over to Preston and returned to I-90.

Lots of mist comes up from the falls to obfuscate the lens

Just past exit 20, Westly hiccuped, continued on another couple of hundred feet, coughed, then shut down.  I steered to a turnout on the right and hit the switch for the 4-ways.  One thing I like about the older diesels is their simplicity - no ignition system to troubleshoot.  Barring some major engine catastrophe, which I was pretty sure had not taken place, there is either fuel or not. - if there is not, it doesn't run.  Lots of air was visible in the line, so I could see right away the injector pump wasn't getting fuel.  I didn't initially think the tank was dry because the needle was not yet buried in the gauge.  I figured maybe the fuel level had gotten low enough to pick up a bit of muck from the bottom of the tank, so I proceeded to drain the fuel filter.  It has a little valve underneath which makes this an easy task.  Just a dribble.  Now I thought perhaps enough muck had been pulled up to clog the filter.  I always carry an extra and could easily swap it.

Help!

Of course I had in mind that we had joined AAA Washington last fall, but I'm a hands-on kind of guy, so I gave it my best before calling for assistance.  We had selected the Premier level membership which allows towing of up to 200 miles, no charge for fuel delivered and other useful (if you have the bad luck to need them) benefits.  AAA, to it's credit, considers the Westfalia camper to be a passenger van rather than a motorhome which keeps the annual fee reasonable.  When it was all over, I figured this episode alone would have cost at least 1/2 of the membership fee if paid out of pocket.

After messing around with the filter, the engine still wouldn't start and the battery was beginning to weaken so I finally did call.  The operator was very thorough and gave me a choice - either have fuel delivered, or a flat bed could come and take Westly to my choice of locations (including home - about 25 miles).  I liked having these options, and chose the fuel.  Within a few minutes, Doug from Ruby's Towing in Issaquah called and gave me the same options, adding that I could have fuel in 15 minutes, but the flat bed might not arrive for an hour or so.  Van Kid was excited about riding in a tow truck, but again I chose the fuel.

Ruby's delivers - Thanks Doug

Fifteen minutes later, Doug showed up with four gallons of diesel fuel ($18.20 worth).  He dumped it in the tank and hooked up jumper cables to provide a little boost.  After some cranking to fill the lines and filter, and a fit of spluttering, Westly's engine roared to life with a brief puff of sooty smoke.  We thanked Doug and continued on our way.  If you ever need towing or other assistance along I-90 in the vicinity of Issaquah, I highly recommend Ruby's Towing (425) 391-3867.

Now, this is unusual for me, but mind if I rant for just a minute?  We were at the side of the freeway for over an hour with the flashers on , the back hatch up and the engine cover off.  During that time among the thousands of cars and trucks that passed by in our direction were three vanagons, including one Syncro Westy with skis on top and no one stopped to offer any help.  Sure, this time I had it under control and didn't really need more help, but what if I was stuck somewhere remote like Bummerville, CA?  Would anyone stop to at least say "Hi, nice van - uhh...why is that big puddle of oil underneath?".  Isn't that in the unwritten code of ownership?  C'mon, where's the love, man?  This served to strengthen my resolve to always help out another stranded Vanagon or classic air-cooled driving Sister or Brother.

See you on the road...

Westly's Specs

Some information I've collected about Westly.

Probably more than you ever wanted to know, but here goes:

> Manufactured in Hannover, Germany March, 1982

> Camper conversion done by Westfalia-Werke in Rheda-Wiedenbrück, 
    Germany July, 1982.  It was imported to the U.S. arriving at Terminal Island,
    a facility shared by the ports of Long Beach and Los Angeles, CA.


> Drivetrain configuration - rear engine, rear wheel drive (2 wheel drive)

> Engine - 1.9 liter inline four cylinder diesel   1Y - manufactured in Mexico
                 Normally aspirated (non-turbo)
                 Mechanical fuel injection
                 Bore 79.5 / Stroke 95.5 / Compression Ratio 22.5:1 
                 Horsepower 68 @ 4400 RPM / Torque 95 ft/lbs @ 2500 RPM
                 Redline 4600 RPM
                 Oil Pressure:
                 60-80 psi cold / 30 psi @ 2000 RPM, 220 deg / 5-10 psi idle, 220 deg 
   * Note:  Original engine was a 1.6 liter 48hp diesel
                The current 1.9 liter was installed 12/2002

Listen to Westly's engine purring, complete with squeaky alternator belt

> Cooling system capacity - 4.2 U.S. gallons
   Radiator core size 22.5" X 17.25" X 1.625" / Hose size 1.25"
   2-Speed electric auxiliary cooling fan behind radiator


> Fuel Type - Diesel #2 or B5, B20, B99 Biodiesel
> Fuel capacity - 15.9 U.S. gallons
> Fuel economy - Mixed city/hwy - 26mpg
                            Hwy @ 45-55mph - 30mpg
                            Hwy @ 60-65mph - 23mpg  


> Transmission - 091 DZ 
   Gear Ratios:    1st gear 3.78
                           2nd gear 2.06
                           3rd gear 1.26
                           4th gear .85
                           Reverse 3.67
                           Transaxle Final Drive 5.86


> Suspension, steering, brakes
   Independent front & rear coil spring suspension
   Rack & Pinion steering
   Power assisted brakes - 10.9 " front discs, 9.9" rear drums


> Wheels & Tires (stock size)
   Steel wheels / 14" diameter / 5.5" wide / ET35 / 5X112 bolt pattern 
   Lug nuts/bolts 14mm thread / 19mm head / 130 ft lbs torque
   Nexen 185R14C LT - Load range D / 8 ply rating 
   Capacity - Single 1875 lbs @ 65psi
   Revolutions per mile: 809
   Go Westy hubcaps (hey, they came with the wheels/tires)

> Dimensions / Weight capacity
    Length - 179.9" / 14.99'
    Width - 72.6" / 6.05'
    Height - 80.7" /  6.73' (with Westfalia Pop-Top closed)
    Ground Clearance - 7.5"
    Front/Rear Track - 61.8"
    Turning Radius - 34.5'
    GAWR Front - 2425 lbs
    GAWR Rear - 2866 lbs
    GVWR - 5292 lbs dry

>Color:  LH8B - Assuan Brown

> Interior: KW - Van Dyck (seat upholstery & curtains)

> Model Trim L includes: 
    Dual outside mirrors
    Sliding side door
    Sliding side windows
    Opening wing windows
    Tinted glass
    Rear window defroster
    Two speed / intermittent front windshield wipers
    Padded dash board
    Instrument cluster with speedometer, odometer, fuel lever, 
         water temp, analog clock
    Heater/defroster/fresh air circulation with 3-speed fan & rear outlets
    Two 12 volt outlets
    Radio with 4 speakers

> Westfalia Conversion includes:
    Front bucket seats with swivel bases, cloth/vinyl covering
    Rear bench seat folds out into bed with storage underneath
    Seat belts for four, front shoulder belts
    Hanging clothes closet with mirror inside door / rear storage compartment
    Clothes locker with three compartments
    Overhead storage compartment with useless cargo net
    Stainless steel sink / 11 gallon fresh water tank / electric pump and faucet
    Two burner propane stove with stainless with fold down splatter shield
    2 cubic foot refrigerator operates on propane, 12 volts or 110 volts
    3 gallon propane tank
    Information panel showing battery charge, fresh water level, fridge on
    110 volt duplex with 15amp circuit breaker
    12 volt overhead light
    Two stow away tables, front and rear (Westly's front table is missing)
    Curtains all around, including front windows and windshield
    Snap-in bug screen for rear hatch
    Fiberglass pop-top with canvas sides, front zipper window with bug screen
    Fold out double bed in pop-top
    Cargo carrier with tie down loops on roof

    
> Some modifications I've made:
    Extra gauges
    Engine block heater
    Larger oil/water heat exchanger 
    1.5 amp 3-stage on board battery charger
    Variable delay windshield wiper relay
    Valve to control heater flow
    Switch to manually engage auxiliary cooling fan
    PO added heavy duty tubular bumpers, front & rear

> Some modifications / improvements specific to the camper:
    Battery operated LED lamps
    Marine fire extinguisher
    Portable solar panel
    Added valve to fresh water tank drain cap
    Added valve and hose to sink drain
    Added T in propane line to use disposable 1 lb bottles if tank is empty
    Cover for refrigerator flue vent
    In/out wireless min/max temp gauge
    Stove/sink exhaust fan
    Plexiglas sliding window rain shield
    Rear table height extension
    Stand to use table outside - hooks into side jack point
    Replaced 110v outlet with GFCI duplex
    Waterproofed pop-top canvas
    Shadyboy awning


>  Technology
    Westly is a computer-free vehicle by birth. 
    I usually carry a cell phone, a GPS,  and a Kindle Keyboard.
   
>  Improvements I'd like to make in the future:
    15" wheels / tires
    New shocks & springs
    Extra battery for camping
    Solar panel to charge the extra battery
    Skylight in pop-top
    New three-window pop-top canvas
    Hella 500ff driving lights
    2" receiver on rear for bike rack
    Upgrade radio & speakers


>  Karma

    Just for the record, Westly was not named after the GoWesty mascot.  In fact, I was mortified to discover they had such a thing and that I might be accused of being so un-original as to emulate their cagey bruin.  He was in fact named after the son of a good friend of mine, but once you bestow a name you can't very well take it back.