Volkswagen Caravelle C T25 1985

[ansarghani]

The interior looks fresh and fantastic.
Those brake and clutch pedal pads may need changing to match the flawless surroundings.

[xenerking]

in fact, the brake pads etc look fine to me....just need a little treatment with a toothbrush and mile detergent..after that they end up like new ones.

[msabbasi]

@ansarghani and @xenerking With regards to the brake and clutch pedal pads, It did occur to me to replace them as now they look a bit sad compared to the rest of the driver cabin. But here is the thing. They cost about 4 GBP each, not much for the pads but the postage here is about 30 GBP (they charge a min of 30 GBP) and then there is the custom duty on the total landed price of 38 GBP which will be about Rs. 2700 or so. That brings the total will be in the range of Rs. 8100. I cant seem to get myself to pay that much for just the look of pedal rubbers. However If I do another bulk order for other parts then I may include these two as it ends up cheaper due to savings on the postage.

[Xulfiqar]

Some shops in Karachi rubber market used to sell local made pedal pads that made factory ones look like recycled garbage.

[msabbasi]

Agreed. Many moons ago I bought a Triumph T100 Tiger. Back then I was working in Karachi and got all the rubber items (foot pegs, kick and grips) locally made complete with the Triumph logo!! If memory serves, the shop was on Barnes Street - Just a little shop but he sure had quite a treasure.

[Xulfiqar]

yes, you got it right. small tiny shop

[msabbasi]

Glad to know my brain still has a few grey cells working. I was remembering things from 1986!!

[msabbasi]

I have a question or rather I need help with a minor issue. This van has hydraulic lifters. If the van is not used for 3-4 days, one of the tappets becomes noisy. previously it was the cylinder No. 1 exhaust and now it is the cylinder No. 2 exhaust. I had the valve cover open on the right bank and had a look see in there to see what was going on. In the case of the three quiet tappets, I was unable to over come the oil in the lifter with my finger while in the case of the offending lifter, I was able to press it. It seems that the oil drains away and in the case of one random lifter, doesn't want to fill up.

Back when the engine was apart, the mechanic emptied the lifter assemblies and refilled them with clean oil and pressed back the tiny "pistons". Any help will be appreciated to shed light on this strange phenomenon.

I will put more observations here as time passes and I learn more.

[msabbasi]

A further update: as already mentioned, I poked the "slack" tappet. I pushed it with my fingers a few times, then drove to a shopping arcade about 0.5km from my place, turned off the van. Came back started it up and it sounded absolutely normal. So for the time being the problems has gone away. Now as a test case, the van will not be driven for the next 3-4 days and I will see what happens.

[Xulfiqar]

hydro lifters will pump up themselves eventually, but usually a sign like this means you need to replace them - buy a new set and install. It will keep on going for another decade with this clangy noise at startup though.

Also - the oil viscosity being used is critical to operation of the lifters.

[msabbasi]

hydro lifters will pump up themselves eventually, but usually a sign like this means you need to replace them - buy a new set and install. It will keep on going for another decade with this clangy noise at startup though.

Also - the oil viscosity being used is critical to operation of the lifters.

Thanks for your input. Hummm. Well, the manual says to use 20W/40 or 20W/50 for temperature above -10C. That's what I am using. So oil viscosity is as per what is called for. Now remains the lifters themselves. Perhaps I did not mention that when the noise comes, it did not go away throughout the drive. Means if I drove for 5 kms, the noise stayed. Now, after I poked about with the offending one, it has gone quiet. As long as no actual damage will take place in the event that it becomes noisy again, I can live with a bit of tapping.

[msabbasi]

On the lifter front, now ten days have passed and they are quiet as mice. Ma Sha Allah the engine is running pretty smooth.

A few pictures to share below as the van discharges its duties without complaining too much.

Just got home after my wife and I bought a 4 poster full king size bed with 2 side tables

The folks at the furniture showroom were not sure the van could swallow up all this stuff

There is place for more. Finally the wife had a bit of admiration for the van.

[capsat]

There is place for more. Finally the wife had a bit of admiration for the van.

and we all have inspiration / admiration for your determination & focus over the van to be working and to be in its actual shape.

[msabbasi]

Indeed. I still need to work on getting it just right but the better half has forbade me to work/spend any more on the van. So I am in a bit of a fix. There are still the brakes, a/c and the front suspension in need of work. Oh yes and the electrics also need a bit of neatening up. But in order to maintain harmony, one has to make sacrifices so for the time being no more work on the van.

[capsat]

the electrics also need a bit of neatening up

i'd recommend invite @margallar to help on & off as you plan, a good snack treat and you will see good clean help he is good with looming & wiring he was part of NUST team which had a podium finish in Kuala lumpur Shell eco-marathon May 2019.

@Xulfiqar will vouch for him as YOUR assistance !

[msabbasi]

@margallar is know to me. No doubt he is talented. The wiring issue is more a mater of a reversing all the "fankari" of the "ustaads". and removing the untold relays fitted everywhere. Basically returning it to factory wiring. All required drawings are with me and it is just a mater of rolling up the sleeves and getting down to it; better half permitting.

[msabbasi]

Running Issues: Yes the van is performing its duties as requested, but I have appalling fuel consumption. Friends also operating VW vans tell me that they get about 10 km/lit from their vans. I on the other had will be lucky to get half that. The engine is in good tune - the exhaust is brown and has zero carbon deposits. The issue at hand is dragging brakes. It has gotten worse with use. What I think is happening is that the brake fluid is not returning back to the reservoir after I let go of the brake pedal. However once the van is standing over night, by morning the brakes are free. In post # 309, I ordered rear brake shoes with the idea to replace them. But now I think what is needed is a full brake rebuild.

Additional parts I will need are:

1 - Master cylinder
2 - All four brake hoses
3 - Rear wheel cylinders.

Front brake calipers seem OK. These parts have been ordered and should be here next week InSha Allah.

Oh yes, I also ordered the brake and clutch pedal rubbers

[capsat]

dragging brakes

till such time brake parts arrived. open up the rear drums & use WD40, the springs may have caught rust again declining to retract the shoes home rapidly. You may also use WD40 silcone lubricant over front clipper pins for smooth return to home position when pedal is released.

[msabbasi]

@capsat InSha Allah the parts get here on Friday. So the plan is to open up things one time and do all the work including wheel bearings. More difficult is to get the local VW "ustaad" to give an appointment.

[msabbasi]

Running Issues cont.: As per plan the brake parts arrived today:

Master cylinder, two wheel cylinders, brake switch and an indicator relay (not brake related). Also got the new brake and clutch pedal rubber pads

Front and rear brake hoses

With all these parts, I am good to go for the brake overhaul. Front pads are good and I am hoping that the calipers are good. If I find that the calipers are bad, I'll see if they can be re-sleeved. If not, then I'll go for new ones.

Now next step is to get an appointment with the doctor