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Volkswagen Vanagon: 1980-1991 (T3) 88 Carat--broke the defrost cable I think


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Last Post: Oct 30, 2009 9:18 PM Last Post By: tcovenant2000
markymarkvw

Posts: 168
Registered: 11/18/06
88 Carat--broke the defrost cable I think
Posted: Oct 25, 2009 10:02 PM
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I bought off of a church a donated 88 Carat. Had almost a brand new motor installed just prior to it being parked.

Great van, sat for 3 years. Some of the plastic has taken its toll.

The heat seems to want to stay on. Now this morning I broke the back of the HVac control unit. I need
to remove the face of the controls to check if the end of the cable came off, or broke.

SO, how do you best remove the panel? Thru the radio or remove the cluster?
FKH161

Posts: 5,903
Registered: 12/29/05
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 25, 2009 10:09 PM   in response to: markymarkvw in response to: markymarkvw
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To get at the whole cable assembly, you need to remove the
instrument cluster from the dash.

As for the heater panel:
- the heater levers pull out
  • the blower motor know also pulls out
  • the heater panel/face plate is held to the dash by two pins
  • use a flat screwdriver and insert it under the panel and
give it a twist, to lift/raise the panel from the dash at
either end of the panel plate

edit-

cable instead of lever assembly

Message was edited by: FKH161

markymarkvw

Posts: 168
Registered: 11/18/06
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 26, 2009 11:15 AM   in response to: markymarkvw in response to: markymarkvw
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One more question on the 2.1 run-ability issues.

Going across a parking lot slowly in 1st gear (standard shifts) both my 87 and my 88 buck and bounce like
there is some micro switch acting up.

I read on VolksCafe website about some micro switch at the throttle body, but I cannot locate one on either of my vans.

I am almost sure the bucking is related to the idle control, but not sure

Has anyone ever worked up a PDF whereas one can walk thru a series of checks on these TB's?
FKH161

Posts: 5,903
Registered: 12/29/05
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 26, 2009 2:26 PM   in response to: markymarkvw in response to: markymarkvw
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The micro switch is on the bottom of the TB.

The wiring harness to it is located on top of the #1 intake
runner (2 wire harness).

When the switch is adjusted too tight, it does not release
early enough when the TB opens... the computer then cuts
fuel at around 1800rpm and that's when you get the bucking cycle.
markymarkvw

Posts: 168
Registered: 11/18/06
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 26, 2009 8:43 PM   in response to: FKH161 in response to: FKH161
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OK, so I adjust it which way...
what am I doing to the micro switch...
TomB

Posts: 1,207
Registered: 08/06/02
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 26, 2009 10:28 PM   in response to: markymarkvw in response to: markymarkvw
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There are two allen-head (small) bolts on the mounting plate. One tightens the switch in position, the other adjust an eccentric to adjust the trip point. If it's quiet you can hear the click as you start to open the throttle. The switches tend to develop more dead-band as they wear, so it won't open and close at the same position. It should click as the throttle comes off the stop, and must click again as the throttle closes. Spec is for a point of .002-.004" off the throttle stop.
markymarkvw

Posts: 168
Registered: 11/18/06
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 27, 2009 9:00 AM   in response to: TomB in response to: TomB
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K...

Going to work on both vans this morn. Neither one can I hear them click like I do on my 16v Passats or 16V Jettas or even the 8V Jetta daily driver

stay tuned!
tcovenant2000

Posts: 1,278
Registered: 12/09/03
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 29, 2009 10:41 PM   in response to: markymarkvw in response to: markymarkvw
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The switches are easy to find. Fry's electronics has them. Any pinball machine parts house has them. You can also get them from Mouser or Newark electronics.
They're cheap, too!
If the motor is off and you can't hear them click as you open and close the throttle by hand then they should be replaced. They are integral to the engine/idle management system (especially if you're running CIS-E or digi...I don't remember which system is used on which vans at the moment) and need to be working properly and adjusted properly.

Thomas
FKH161

Posts: 5,903
Registered: 12/29/05
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 30, 2009 1:08 AM   in response to: tcovenant2000 in response to: tcovenant2000
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Attachment throttleswitch.jpg (18.4 KB)
The Digi switch for the Vanagon's looks like the attached image...
tcovenant2000

Posts: 1,278
Registered: 12/09/03
Re: 88 Carat--broke the defrost cable I think
Posted: Oct 30, 2009 9:18 PM   in response to: FKH161 in response to: FKH161
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Yep. You can still use the ones from pinball machines, coke machines, etc. Just drill out the rivets and replace with #4 bolts and nuts instead of rivets.

Thomas

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