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Re: Heart transplant complete: New 2003 VR6 Golf/Jetta motor into 2002 EV WK

 

My only questions are is there a difference in camshaft lift/duration on
Eurovan VR6s verses the Golf/Jetta/Corrado VR6s and if so, how will it
affect mileage and/or performance in the long run?

Just curious....
--
Jim Thompson
84 GL 1.9 "Gloria"
84 Westfalia 2.1 "Ole Putt"
73 K Ghia Coupe "Denise"
72 411 Station Wagon "Pug"
oldvolkshome@...

On 6/16/08, rensho68 <rensho@...> wrote:

4 weeks ago, I bent a rod in my well loved EV. I was sick to my
stomach. I found little in the way of VR6 AXK motors. One used one
was $4000 for a long block. That was just wrong.

My motor had 170k fwy miles on it. Seems high, but the thing ran like
a champ. Choices were to find a donor, or rebuild. I looked at all
the costs of a rebuild, and time away, and it wasn't a great option
either. My motor needed a timing chain tensioner examination, as per
typical mileage. It also needed a new WP, as per mileage.

A quick a dirty option was to pull everything and shove in a new rod
and or piston.

I found a new remanufactured VR6 longblock for $1999 shipped. It was
a BDF motor. I could find no one, no source, to tell me if the blocks
would work, line up with the tranny, and or if the heads would fit in
nicely. This block would be a automatic block. The block had a new
head, all new seals, a seal kit for the rest of the install, new
cams/chains/tensioners. All this assembled by the factory, with full
test readouts of oil pump pressure and cylinder PSI.

The motor arrived and the old motor was in the van. One tranny
bolt/dowel wouldn't line up, about 1.4" different.

Long story short, I ground a channel in the block to make the bolt
slide by into the original tranny hole. This allowed the substantial
head of the M12 bolt to grab the back of the block, and hold it tight.

Lessons:
1. A BDF block and head works just fine. YOU NEED A MANUAL BLOCK,
unless you want to grind the channel through 1" of iron like me.
2. The tranny can stay in place, with the axles, balljoints, etc,
while the long block gets pulled out through the front of the van. I
did this with the front of the van lifted about 6-8" off the ground.
3. The cam sensors wires are the same darn plug, since it uses the
same sensor part. Make sure you mark this, or take pics. I plugged
them in wrong, and luckily the van drives just fine. Power was down a
tad and it threw a code.
4. With the tranny in place, installing the engine was a big task. It
took 4 of us with a engine hoist, and a jack, and 2 hours to fit it.
The angle of the block presents the biggest problem, along with the
stock lifting points of the engine.
5. That special engine jack mount (bolts to bottom of block) shown in
the manual would be a lifesaver for the install. That would have
saved 2 hours for us.
6. Don't start this job without the 6 and 10mm triple box drivers.
You'll need the 12 for the axles or head bolts.
7. Part way through the 2002 model year, VW changed the WP on the EV.
The later VINs use the same WP as the BDF motors.
8. Buy all new exhaust nuts. They are crush nuts, and are not common
to find. Don't doublenut install studs with the old crush nuts,
they'll ruin the threads of the new studs. Use some 8.8 or higher nuts.
9. My WP impeller had ~1/2 of its blades worn/broken away. Stupid
plastic part. This most likely caused my old tranny temp to be 10+ F
higher than typical.
10. Those fuel injector seals are a small fortune. Don't ruin them.
If you need them, your dealer has them for $22/ea set. You need 6
sets! Cheapest online was around $15/set. Lame for 3 ordinary black
rubber o-rings.

We installed the motor back in and fitted all the panels and drove the
van within 6 hours. I'm a happy 'camper' again. :-)

As a super bonus, I bought a Scangauge/Xgauge thing. They have a code
that you can input and it displays tranny temp!!! How cool is that!
On a small little gauge face, I can see 4 things, and scroll through
another ~15 readings. I have mpg, trip mpg, tranny temp, and engine
water temp or voltage typically displayed. I can designate any of
those 4 fields to be any of those ~15 things. Awesome.

Hope none of you guys need the info above any time soon. ;-)


PS, at many points during the process, I strongly considered adding
complexity to the project and install a manual 6sp, since the engine
mating issue was already a problem. The 6sp trannies are cable
shifters, so that really wasn't an issue.




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--
Jim Thompson
84 GL 1.9 "Gloria"
84 Westfalia 2.1 "Ole Putt"
73 K Ghia Coupe "Denise"
72 411 Station Wagon "Pug"
oldvolkshome@...


Re: What does ECM mean by "pending?"

 

-The ECM has seen a problem and has flagged that code in memory. If it continues to see a
problem with a misfire on a particular cylinder for example it will then set a "hard" code and
trigger the light. If the problem corrects itself and goes away it will still keep the pending
code is memory until someone clears the codes. Rick.


5 - speed transmission problem

 

Sorry, I meant 1994 diesel eurovan, not 1984!

Hilary


5-speed transmission problems

 

Hi there,

We have a 1984 Diesel Eurovan (with Westfalia). Here's the problem:
As soon as we've been cruising on the highway for a while, but then
have to downshift to 4th to go up a hill, the gear shift goes into
spasm and we cannot shift after that into any gear, or we have to
force it, or stop at the side of the road, turn off the engine and
start again. Two different shops couldn't find anything. Does anyone
know what it could be? We don't even want to drive the thing now!

Hilary


(No subject)

Dale Lucas
 

Allen,
We just got a set of factory 16s for our 97 EVC, now&nbsp;we need your tires.
We&nbsp;live in Oregon and will pay the freight.
Thanks,
Dale, 97 EVC w/ 16s
Portland, Oregon
971 570-0679


Re: Is it possible to modify EVC Van Air Conditioning?

leslie.gilpin
 

Maurice, I am trying to solve this too. Look at www.swampy.net. They
have 12V evaporative coolers (dry climates only) and 12 "dual"
ac/evap coolers using an ice water solution that use your coach
battery or convert 110 to 12 V with a converter if you are near shore
hookup. On the expensive side but I plan to use my van for at least
10 years (just go it 2 months ago) and I can justify the price tag.
I'm going for the MK4 model.

Les

--- In ev_update@..., "moedig" <maurice@...> wrote:

Is it possible to modify EVC Van Air Conditioning while camping?
Being
really naive about how the A/C works in the EVC, is it possible to
modify it so that I could flip a switch and the
compressor/condensor
fan and all other components could work off the battery/Inverter
Shore
power?

Thanks,

Maurice


Re: EVC Goodies: Online Tag Sale

 

Please contact me if you have the screens available still. Thanks Bob
xyourobob@...



--- In ev_update@..., ed davis <davisea@...> wrote:

If they are still available, I'll take the screens. I live in the
Boston area and can pick them up, but it'll be a little while. I am
presently camping in Myrtle Beach.

Anyway, if you'd like, I'll pay you the $250.

Regards,
Ed

'99 EVC

eapling <EApling@...> wrote: Do you
still have the screen set? Thanks,Elden--- In
ev_update@..., "allenberrien" <allenberrien@> wrote:
>
> Greetings:
> A few years ago we traded our 2002 Eurovan Camper in for a
Rialta
22QD. I have some
> accessories left over from the EVC which I would like to sell.
Here's a list:
>
> ? Side tent. Can't remember the model, but it's one of the
German-
made side tents that
> are compatible with the Eurovan and EVC. Paid about $600.00 for
it.
It was pitched just
> once and has been stored in a dark, dry, mildew-free place since
then. How about
> $425.00? (Not including shipping, which we could discuss; it's
big
and heavy.)
>
> ? A complete set of nylon screens. This set of five custom-
tailored screens fit the back
> hatch, the side sliding door, the rooftop vent, and the left and
right cab windows. I don't
> know how you could survive without these in buggy country. They
allow you to leave the
> camper open to whatever breezes there are, while maintaining a
BFE
(bug-free
> environment). You will need to provide the self-adhesive Velcro
tape (the fuzzy side) to
> install them in your EVC, but they are in perfect shape. They
were
stored in the same
> place as the tent. The set sells for around $410.00 new. These
are
in mint condition and I
> will sell them for $250.00, including UPS ground shipping within
the continental US.
>
> ? A custom-made rooftop cargo bag. This was fabricated by
Kirtland
(Kirkland?) Canvas of
> Salt Lake City. This group did a group buy of this bag quite a
few
years back, perhaps in
> 2003). It is designed to fit into the recessed well on top of
the
cab of your Eurovan
> Camper. A flap-covered, super-duty nylon zipper goes around
three
sides and straps
> secure it to rustproof metal cleats which are screwed to the
fiberglass cab roof. Most of
> the members who participated in the group buy had their bags
fabricated from standard
> canvas. I paid a bit extra and specified vinyl-coated canvas.
This
thing will swallow up a
> couple of small camp chairs, the side tent, and a charcoal
grill.
The price for this item is
> $65.00 including UPS ground shipping in the continental US.
>
> ? Fiamma bike rack. Custom-fabricated to attach to the back
hatch,
which can still be
> opened with the bikes mounted. It's made of mandrel-aluminum
tubing
and
> accommodates three bikes. Pretty cool. Slightly beat up yet
perfectly serviceable. Sells new
> for $360.00. How about $165.00 shipped UPS ground continental US?
>
> ? Tires, tires, tires. I have eight Michelin Energy XSE
22560R16
tires for the late-model
> EVC with the 16" wheels. Three of them are moderately used and
five
are brand-new,
> never been mounted. They've been stored standing up in our
cement-
floored crawl-space
> for a few years. As I understand it, even properly stored, tires
should be used within seven
> years or something like that. So someone should get them on a
van,
so they're used up
> well before that time. I got these on the cheap, when VW had a
closeout on them. A buyer
> could pick up all eight of them for $200.00 at my house in
Western
Massachusetts. I
> would rather sell them to someone who will pick them up here,
because shipping them
> would be a pain, but if you're not nearby and you're interested,
let's talk.
>
> If any (or all) of these items are of interest to you, PMail
me
at:
> 2002_rialta@
>
> Best/Allen
>








93 manual trans shifter bushings (?)

 

Would someone mind describing how to replace the darn bushings
in the manual trans shifter...they were replaced about 20K ago
(by local indy), but today I suddenly had nothing but extreme play,
especially to the right, and access to 3rd and 4th gears only.

If this is gonna happen every 20K or so (seems a little premature in
this instance), I better get it figured out.

I'm not mechanically inept, but brief descriptions I'd read a koupla
years ago on this didn't seem very clear. Any help appreciated.

Dale M
Fayetteville AR


Re: Trouble reattaching speedometer cable

Joe R
 

I don't know if you know this but it's a 2 piece cable set. One piece just goes to the area under the hood where the battery is. You can disconnect it there to get more play. The second piece goes down to the transmission. When I did mine it actually pulled apart there.

Joe R

----- Original Message -----
From: David
To: ev_update@...
Sent: Monday, June 16, 2008 3:44 PM
Subject: [ev_update] Trouble reattaching speedometer cable


1993 -- removed instrument cluster to perform voltage stsbilizer fix.

With cluster reinstalled I am having a devil of a time getting the
speedometer cable to seat properly. I got it to where I thought it was
ok, but speedometer needle doesn't move.

Is there some technique/trick to get the cable seated?


Re: Random Lock and Unlock on 2002 EVC

Ariel Calonne
 

On my '99 GLS, I think there is some plastic dohickey in the
passenger door that basically holds the lock in the up position. It
has broken off. I have tried many times to fix it, including
replacing the lock motor (needlessly). I think you'd have to replace
all those clear plastic hidden guts that sit right under the push
down part of the lock behind the sheet metal. I afraid to ask the
dealer because I do wish to eat for the remainder of this year, so I
am living with it. It makes for fun at car washes and a spare key is
advisable.

I'd love any advice if anyone has a more analytical response.

Ariel Calonne
'99 GLS 97k
Santa Barbara, CA

--- In ev_update@..., "moedig" <maurice@...> wrote:

Hey all... just recently my doors started to lock and unlock only
after
the van was started. Any ideas what could cause this?

- Thanks!


Re: What does ECM mean by "pending?"

dave803wms
 

"Open the pod bay door HAL"! Dave

--- In ev_update@..., "pkgloger" <pkgloger@...> wrote:

I'll take that warning very seriously, 'cause if anybody would know,
it'd be you, DAVE!

Paul in Pittsfield

--- In ev_update@..., "dave803wms" <dsbauer2@> wrote:

Maybe it's something like HAL, the mis-programmed computer in "2001
- A Space
Oddesy" that reported a pending failure of a part outside the
spacecraft so it could lock
the astronauts out and take control itself. Be careful!

Dave


Re: Is it possible to modify EVC Van Air Conditioning?

 

In a message dated 6/16/08 11:28:37 PM, leslie.gilpin@... writes:


Maurice, I am trying to solve this too. Look at www.swampy.net. They
have 12V evaporative coolers (dry climates only) and 12 "dual"
ac/evap coolers using an ice water solution that use your coach
battery or convert 110 to 12 V with a converter if you are near shore
hookup. On the expensive side but I plan to use my van for at least
10 years (just go it 2 months ago) and I can justify the price tag.
I'm going for the MK4 model.
Interesting......but very expensive, some as high as $900.
The only advantage I can see is that they will 'work' from a 12v deep cycle
battery when shore power is not available. They also seem to be large and take
up space.

A 5000 to 6000 btu refrigerative window air conditioner costs only about
$100-130 at Walmart, Home Depot, Lowes, etc., etc. It will last for years, but
does require a 110v shore line.
Mounted in the overhead luggage area or either driver or passenger window, it
will nicely cool an EVC.

I used to have mine permanetly mounted in the overhead luggage area during
hot months but now carry it inside and 'install' it when I get to a site. This
way there is less wind resistance and better gas mileage.

Kent Kirkley
'97EVC




****
Gas prices getting you down? Search AOL Autos for
fuel-efficient used cars.
()


Re: Tires again

 

I just got done mounting a set of 235/60X16 Yokohama TRZ tires on Mercedes 7.5" wide alloys on our 99 EV GLS. Used centering rings and had to purchase longer lug bolts. The combination works great with plenty of room all around. The wheels have a 46mm offset.

The load rating on the tires is 99T, which is fine for the way we use our van, but I'd want to double check with the camper. The physical size sould not cause you any problem, unless there is a difference in the way the two model years are suspended.

R T McSherry
Norway, ME


Re: Random Lock and Unlock on 2002 EVC

 

This happened on our 93 EVWK. Turns out it was the wires that pass
through the A-pillar into the door. I slide back the bellows with the
door open and saw cracked insulation on the wiring. I removed the
door panel, the drivers kick panel, unplugged the harnesses from
everything, fed them back through the door into the vehicle so I could
wrap them nicely, broke out the electrical tape and went to town.
Reinstalled and haven't had a ghost lock since (about 6-8 months now,
used to happen every time I started the car, among other times).
YMMV, but good luck.

Bill

--- In ev_update@..., "moedig" <maurice@...> wrote:

Hey all... just recently my doors started to lock and unlock only after
the van was started. Any ideas what could cause this?

- Thanks!


Random Lock and Unlock on 2002 EVC

 

Hey all... just recently my doors started to lock and unlock only after
the van was started. Any ideas what could cause this?

- Thanks!


Re: Two questions re Wet Okole and top on EVC - thanks

 

The rear bench stll works fine. The covers are in 2 pieces and dont
interfere with mobility or removal. Only thing is if you get piping
you might feel it if you sleep on it.
--- In ev_update@..., "Ed Brady" <electicamp@...> wrote:

Thanks, all, for the helpful replies.

-- In ev_update@..., Larry Schellhase <schellhase@>
wrote:

I know Sportsmobile offers a power
top on their pop-
tops, however they use a completely different mechanism and
vehicle. But you could give
them a call to see if there is any chance it could be adapted to
the EVC.

Larry

--- On Sun, 6/15/08, Ed Brady electicamp@ wrote:
From: Ed Brady electicamp@
Subject: [ev_update] Two questions re Wet Okole and top on EVC
To: ev_update@...
Date: Sunday, June 15, 2008, 3:41 PM











I did a search for Wet Okole and found some good
information. We have a
German Shepherd

(German Shedder?) and I believe the Wet Okoles would be a good
choice. Here is my

question. If we add Wet Okole covers will the rear seat still
work smoothly when making
up

the bed in our EVC?



I also did a search for power tops and found nothing. Does
anyone know of a
modification to

electrically raise and lower the top? Lots of custom
convertibles and other custom cars
are

being made with power operated gadgets, so I bet it is possible,
but has anyone tried it?



Thanks



Ed Brady





























[Non-text portions of this message have been removed]


Re: Tires again

 

They should work, for the '01 and up that is the Plus 0 size for the van.

Chris Lindenberg


Re: Two questions re Wet Okole and top on EVC - thanks

 

Thanks, all, for the helpful replies.

-- In ev_update@..., Larry Schellhase <schellhase@...> wrote:

I know Sportsmobile offers a power top on their pop-
tops, however they use a completely different mechanism and vehicle. But you could give
them a call to see if there is any chance it could be adapted to the EVC.

Larry

--- On Sun, 6/15/08, Ed Brady electicamp@... wrote:
From: Ed Brady electicamp@...
Subject: [ev_update] Two questions re Wet Okole and top on EVC
To: ev_update@...
Date: Sunday, June 15, 2008, 3:41 PM











I did a search for Wet Okole and found some good information. We have a
German Shepherd

(German Shedder?) and I believe the Wet Okoles would be a good choice. Here is my

question. If we add Wet Okole covers will the rear seat still work smoothly when making
up

the bed in our EVC?



I also did a search for power tops and found nothing. Does anyone know of a
modification to

electrically raise and lower the top? Lots of custom convertibles and other custom cars
are

being made with power operated gadgets, so I bet it is possible, but has anyone tried it?



Thanks



Ed Brady





























[Non-text portions of this message have been removed]


Re: EPC, ESP lights

 

You should get the codes read at your local auto supply store and let us
know what they are.

I had a similar problem (2001 Weekender at about 115,000 miles) and the
codes lead me to the MAF sensor. I cleaned to old one but that failed to resolve
the problem. Bought a new one from Steve at europarts-sd, cleared the codes
and the CEL, and all was well again.

In a message dated 6/15/2008 10:46:46 P.M. Eastern Daylight Time,
gelliott10@... writes:




Today when I went to drive our 2001 MV with 105K, I noticed the EPC
(Engine Electronic Power Control) and the ESP (Electronic
Stabilization Program) lights did not go out. The only symptom I
noticed was a very distinct loss of power starting out. Once we got
going, It drove fine. The manual says to contact the dealer (2 hours
away). We do have a non dealer VW repair shop 45 minutes away. How
serious is this, and what needs to be done?

Gary E.








****Gas prices getting you down? Search AOL Autos for
fuel-efficient used cars. ()


Re: What does ECM mean by "pending?"

 

I'll take that warning very seriously, 'cause if anybody would know,
it'd be you, DAVE!

Paul in Pittsfield

--- In ev_update@..., "dave803wms" <dsbauer2@...> wrote:

Maybe it's something like HAL, the mis-programmed computer in "2001
- A Space
Oddesy" that reported a pending failure of a part outside the
spacecraft so it could lock
the astronauts out and take control itself. Be careful!

Dave