Resurrecting the 1985 Westy

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ajdenette
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Resurrecting the 1985 Westy

Post by ajdenette » Tue Aug 29, 2017 7:08 pm

Well time to start a thread for reviving the 1985 Volkswagen Westfalia.

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This van was purchased brand new by my grandparents and taken delivery of in Germany through the Tourist delivery program, they toured Europe in their latest Westy and shipped it home at the end of the summer becoming my grandmother's daily driver. My grandparents purchase another new Westy(their 5th and final new Westy 4th on the tourist delivery program) and again toured Europe sending the new Van home at the end of the trip. After returning home they tried to sel one of the 2 Vanagon Westfalias but were unable to get their asking price so they parked the brand new van to have when they needed it. My grandmother drove the 1985 daily up until 1993-1994 when it blew the head gasket and it was put aside for another day and the 1987 was taken out freshened up and put on the road. My grandparents have been driving the 1987 since and got another daily driver in the early 2000's and the Westfalia became a spare car so has less than 100,000 miles still. In 2005 While working for my aunt and living with my grandparents we pulled the 85 from the basement of the barn up to the main level where I attempted to perform a head gasket replacement and get the van running again, I never succeeded in getting the Westy running and later learned that I had not replaced the bottom O rings for the cylinder where I believe the real issue is as the failure was coolant and oil mixing. since then I have graduated high school, graduated college, got married, my wife earned a PHD, and we bought a house. My wife and I went camping with some friends late this summer with the Syncro and she realized I had a Westy I just need to do some work on with curtains and a garage to work on it might not be a bad idea. So with permission to bring another car to the house (we have 3 registered Subaru's and the Syncro) time to get it down where I can putter with it.


Last registration
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She is a wee bit dusty
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My Grandparents and much of my family love PEI Canada and is a regular summer vacation destination.
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Alex

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ajdenette
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Re: Resurrecting the 1985 Westy

Post by ajdenette » Tue Aug 29, 2017 7:29 pm

Plans:

The plan to get the Van back on the road is first Clean it up and get it from my Grandparents house to my house. my grandfather has already washed the outside and is cleaning up the inside some from the years of sitting in the barn. I have a friend with a Truck and have a Uhaul trailer reserved for Monday to truck it down to my house.

The engine will be swapped out from the 1.9 to a Subaru 2.2 that came from my fathers 2000 Imprezza outback that had the gas tank and body rust out on him, I have modified the harness and have that sitting in a box. My parents purchased an adapter plate and a carrier bar from Rocky Mountain Westy that we have already installed on the engine, and I plan to use Small car pipes for a non reversed manifold that I already purchased. I had a brand new catlitic converter muffler and full set of pipes for a 1.9 so I bought a subaru header and cut it up and plan to build my own exhaust.

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Next I will also be going through the brakes (replacing pads rotors hoses rear shoes and a through bleeding) and resealing and maybe replacing the gas tank after assessment. I am working on getting a full set of vw alloy wheels and will need to get new tires for them but even decent tires will be better than the ones on the van as they are currently showing the steel cords through the cracked treads. I also hope to switch it over to Truck mirrors as I prefer them over the others for visibility and also a Small car aluminum oil pan plus check out the cooling system and whatever else needs attention due to sitting for about 25 years
Alex

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ajdenette
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Re: Resurrecting the 1985 Westy

Post by ajdenette » Thu Oct 12, 2017 7:03 pm

Well with the help of a friend and his truck I rented a Uhaul flat bead trailer and we headed up to my grandparents house to load it up.

one last picture of the 1987 Westy and the 1985 westy together in my grandparents yard we used the 87 as a test load just to see how things sat on the trailer

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loaded up and ready to move due to the cracks in the front tires exposing the steal cords we let the air out of the front tires and strapped it down like that to make sure there werent any issues in transport

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Finally in my driveway and airing out and cleaning out the mice my grandfather didn't find in his preliminary cleaning.

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we were watching a friends dog for a week and dropping them off and picking them up at the airport so we were going to have a 6th car in the yard with the Syncro in the garage (rotted winshild sill leaks) and my wife's outback wagon in the other bay while I was replacing the head gaskets I needed to get the westy running to move it over in the driveway

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Alex

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ajdenette
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Re: Resurrecting the 1985 Westy

Post by ajdenette » Thu Oct 12, 2017 7:25 pm

So my goal was to get the Westy running so that I could move it around the yard, I drained the 12 year old gas and got some fresh gas in it and decided I should check the valve adjustment and found one of the big reasons for the lack of running was due to 5 of the 8 pushrods not being seated in the lifters so I reseated them. Next was cleaning all of the ground wires and replacing the bolts.

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I did also clean the trans ground strap and replace that bolt as well, I was poking at it and tried to start it with the 12 year old autozone battery I had brought back to like but it did not seem to hold a good charge suprise suprise so I replaced the batter and was in the engine compartment with the remote starter switch and the voltmeter poking and found when I poaked the green coil wires I got a real sputter

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Next after realizing what was causing issues with the not starting was the double connector and was able to get the van to run not well and not controlled but there was noise and fury.

https://youtu.be/uPucFn847iI
Alex

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ajdenette
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Re: Resurrecting the 1985 Westy

Post by ajdenette » Thu Oct 12, 2017 7:39 pm

After getting it to start I added some coolant and another couple of ruff starts i finally got it running and idoling

https://youtu.be/i19fCgnIP8A

Once it was running I was able to move it over in the driveway and able to get 4 cars across for the week. After I got some room in the driveway I had to get a picture of the 2 vanagon’s together in my driveway

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After I finished fixing my wifes outback I finally had both Vanagons in the Garage

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The next biggest issue for moving it around is that is has no brakes the master cylinder has failed and all I have done thus far is move it forward and backward not even getting it fully into gear to not get faster than my brakes could stop me.
Alex

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ajdenette
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Re: Resurrecting the 1985 Westy

Post by ajdenette » Thu Oct 12, 2017 8:13 pm

The next biggest issue for moving it around is that is has no brakes the master cylinder has failed and all I have done thus far is move it forward and backward not even getting it fully into gear to not get faster than my brakes could stop me. While I prepared for swapping the failed master cylinder (could pump up pressure but as soon as you let off the pedal it would go right to the floor) I decided to change the oil after getting it into the garage.

This last monday my father came down and we swapped out the master cylinder after installing a new master and bleeding the mud out of the cylinders and lines we had functioning brakes that held pressure. After that I fired it up and took it for its first drive in a long time and it felt good. Took it for an illegal no plated rotted tires ride around the neighborhood just to put a little load on the engine. Then went on to cut down one of my work benches I got from work to make my garage easier to work in with the harness underneath and the TDI starter on top.

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Alex

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Jadewombat
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Re: Resurrecting the 1985 Westy

Post by Jadewombat » Fri Oct 13, 2017 12:41 pm

Great stuff, keep it going!

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