Brazilian Kombi Air-cooled service manual now online

I am pleased to announce my Brazilian Kombi service manual is now online. See link "Brazilian Kombi Technical Service Manual" Page on the right ->

It has taken be many months of hard work and Portuguese translation to compile this manual for air-cooled Brazilian kombi owners.

Sorry no download just view on-line.

Please feel free to get in touch if you have any questions / comments.

Bay Related Manuals now published on blog

Have a look at the pages on the right ->

There is now a list of useful links which contain pages of VW bay related information.

I have found how you can store google docs documents and embed them into a PDF viewer window.

They are currently only sized window of around 800x1000 pixels as I have not found how to automatically adjust for your browser (HTML is not my thing!)

Also poor on Mobile devices so have disabled this and only desktop site available. You can read the blog on a mobile and still be able to view the PDF.

Hot Start issue - Resolved

Finally got to the bottom of the not starting when hot.

I was doing an oil change and while underneath I had a good look at the starter motor earth cable.

It was not attached well to the Chassis and also badly corroded at both ends. Removed and cleaned both ends of the cable and cleaned both mounting points with sandpaper and wire brush.

Refitted and covered in Petroleum jelly to ensure it does not corrode again.

This must have been causing a bad earth to Chassis for most of the electrics.

So the following issues have been resolved now been resolved.

1. Starts when hot. Starts so much better and quicker than before.
2. Start Battery holds charge.
3. Dash lights and other lights are all bright white instead of dim yellow.
4. Brake warning light does not glow and not affected by clutch pedal.

So everything is resolved and it like having a new van again! Very Happy

Another Day Another Battery Tray

Renewed both starter battery and leisure battery earth straps to try to stop the starter battery going flat.

Not much rust in this battery tray. Treated and painted and all replaced.

This is the Starter battery tray with the new "shiny" Earth leads and replaced crimps.

Still not sure if its sorted the Battery Drain as the Starter Battery had a good charge when removed.

At least they have a "good" earth now.

Next on the list is measuring the current in all fuses to see where the current is going!

Battery & Tray restoration

Time for a new Starter Battery as Betty's battery has trouble starting after a long drive and only giving 11.78V at best.

Strange how the battery was struggling when the engine was warm but it is in the direct flow of the cooling air.

So new Battery was purchased and a free morning to fit it.

The old battery was a 48 A/h 220A and appears to be the original Brazilian battery as it was made in Brazil. So could be from 2004!

Upon removal it was clear that the battery tray was in need of some rust removal and restoration. Major water trap and also a weak spot for any bus.

Rust is only surface but needed treatment before replacing the battery.

After some cleaning and wire brushing the worst was removed. 

Surface treated with Hamerite rust removing Gel. Cleaned back again. No More rust! Then primed with the Hamerite Primer.

Resprayed with Hamerite smooth spray. Quite a good match to the VW Candy White. Close enough for inside the engine bay.

New YUASA 50A/h 440A Silver 5000 Battery. Should last a while and not too big for the Alternator to charge.

Starts after 2 Seconds and totally smooth turn over from the starter motor.

Will now be able to connect the Leisure Battery back up and think about replacing the rubbish split charge relay for a smartcom.

Reasons to be cheerful about your VW camper

Reasons to be cheerful about your VW camper

• IT WILL BE WORTH MORE NEXT YEAR THAN THIS.
• YOU DON'T NEED TO VISIT A THEME PARK FOR A WHITE-KNUCKLE RIDE - JUST DRIVE YOUR CAMPER IN A GUSTY CROSSWIND.
• YOU CAN LITERALLY LOOK DOWN ON ALL THOSE DRIVING FORDS, PEUGEOTS, ETC
• THEY ARE EASY TO FIX AND HARD TO BREAK.
• MECHANICS IN ANY PART OF THE WORLD CAN MAKE PARTS OR REPAIR IT FOR YOU.
• LIVING LIFE IN THE SLOW LANE IS STRESS-FREE AND MUCH MORE FUN.
• YOU HAVE AN UNLIMITED LIFETIME SUPPLY OF FREE COOLANT.
• OIL SPOTS GIVE YOUR DRIVEWAY CHARACTER.
• ANY OTHER CAR YOU DRIVE WILL SEEM REALLY FAST.
• YOU WILL NEVER, EVER SUFFER ROAD RAGE FROM TRYING TO PASS ANYTHING, ANYWHERE.
• THE ENGINE MAKES BETTER NOISES THAN A RAVE BAND.
• YOU GET REALLY INTERESTING SOUNDS WHILE DRIVING IN RAIN. EVEN BETTER SOUNDS DRIVING IN HAIL!
• PEOPLE YOU DON'T KNOW SMILE AND WAVE AT YOU.
• THE UPRIGHT SEATING PROMOTES GOOD POSTURE.

Taken from Campervan Crazy book.

Cylinder Head problems

Started to notice noise coming from Cylinder head 3 and rough running.

Readjusted tappets and found that Cylinder 3 exhaust valve was very tight yet again.

Removed Rocker assembly and found that Exhaust valve spring was 3mm higher than the rest.

Adjustment on that valve was right at the end of the adjustment thread.

Having determined that there must be and issue with this valve (either the seat or a tulip valve) and needed the engine removing and the head removing. The question to be answered was DIY engine removal or get a garage to do the work.

Finally went for the Lions Garage in Loughborough to pull the engine and sort this out. At £50 per hour and a 10 hours work it was going to take.

After 8 days of waiting. The engine was out and it was found that the valve seat had totally become detached from the head and was just loose around the valve seat. Also the head had had a helicoil in that spark plug so was running very hot and destroying itself!

Here is the old head - Wheres the seat!

Got two new heads from VW heritage - Special heads for Brazil bay as they have special 22 fin cylinders and lower compression ratio for the Injection engine. £160 each. Went for replacing both heads so they are the same age and condition. New gaskets and push rod tubes and head bolts to ensure all is good.

All done and running OK. Much smoother and power. Just running in and will reset tappets after a few hundred miles.

Great to have her back but cost £670 in Labour and £400 in parts! Not cheap. Next time I going to remove the engine myself!

Betty Adventures

Brazilian Kombi Brochure

Betty's 1st camping trip

First time camping trip in Betty. Pipe cleaning for a half term get away. All good.