High score!

Got my hands on a complete set of seat covers. Original. Top condition. :-)
Unfortunately it's for a double seat in front so it will not fit the Multivan. But I can use it in the pickup (1+2 seats) and for the rear sofa in the Multi. Surf theme covers in front then!

Coming together

Now everything's coming together again. The gearbox is done, just a few bits n pieces left on the engine. Soon it's put-it-back-in-the-van time!
I need a short pipe to fix my temporary solution for the oil return (temp stuff tend to be stationary...) and mount my new bracket for the old servo pump. I'll make another timing check to be sure it's ok.
Then into the van?..

Bellhousing resto part 2

Some measuring to get the shaft centered and the lock it! The filler is fiber reinforced and pretty strong, but I've added two screws as well to make sure it's fixed. Well it is now. Tomorrow I'll do the last steps on the gearbox and then it's time to move the driveline back into the bus.

Bellhousing resto

The shaft/slave cylinder mount was crap (it was totally corroded off!) so I made a new one out of alu. Everything is press fit including the new plastic bushing. I'll cut off some material from the housing to come closer with the new piece, then build up a better support with filler and lock it up with a couple of screws.
Will be better than the original.

Pump internals

I missed an important image the other day. It's just to show how the impeller should be inserted.

Servo reassembled

The pump is done. It's important to put the 'impeller flags' back correctly. One side has rounded corners and they should be inwards!
Now I only need a few parts made and the pump will fit the engine brackets.

Not so very fun discovery...

Aaaargh!!!
The gearbox is really crap, I knew that. But this was NOT what I expected. Time to make a new alu piece and make some welding...
I had to cut of the clutch arm to get it off. I'll see if the arm in the new AAP is in better shape. But I still have to renovate the bell housing. :-(

Waterpump on a stand.

Tonight I replaced the water pump. It's doable without removing the timing belt and that procedure is so easy now when the engine is on a stand. Now afterwards when I have seen the condition of the old one I think it was a really good idea. :)

I also painted everything in and around the engine compartment with 2K epoxi primer. I think it's worth taking that extra time to do it now, later on when the engine and gearbox is in there it will be a mess to do it. I mean, just brushing of all the sand right now when the bus is empty was a pain and with an engine in the way...

Oil pan switch

Once again, the hand cleaning cream is invalueable as a dirt cleaner, 10 minutes of brushing and the oil pan was nice to work with.

The pan, the oil pump nose and the oil stick is now moved to the TDI. The stick needed a bit of bending and a new mount, otherwise no problemo. Oh yes, you have to remove the flywheel to tighten the rear screws. Really annoying.

Servo pump rebuild

I did notice that the servo pump is pretty dirty and I suspected that the shaft seal is no longer what it should be. So, time to disassemble! There are a lot of toughts and believes about servo's out there, and I think it's time to demystify the poor little bastards.

First of all: Yes, they are units possible to service!

Secondly: It's just a matter of having patience and a clean desk.

Third: It's way easier to disassemble a pump than for example a turbo.

It's really important that the pump is clean before you split it. The smallest sand or dirt can destroy it or make it leaking before you even put it back in the vehicle. In the past I've been using diesel, oil cleaning spray and blah blah blah, but guess what - the hand cleaning soap I have in the workshop is the best dirt killer ever! One pile of the cream and a brush, swipe the part over and rinse. It's clean in a couple of minutes.

The pump is a rotor with a bunch of square shaped loose metal pieces that are pushed out against the elliptic housing (acting like sliding doors), the volume between the clips decreases when the shaft is rotating and the liquid is pressurized and pushed into the oil channel. The flow and the pressure capacity is a combination of the housing itself and the power put into the shaft.

The entire assembly is held together with a single clip. Remove it and you can pull out the shaft. The rotor is usually stuck though because of the oil film on the backside. After the shaft is removed you can push the impeller sideways.

The shaft is surrounded by the pressurized oil and doesn't have a needle bearing or similar. If the shaft sealing is worn out, it will leek immediately as the oil is filling up the housing with pressure all the way up to the sealing.

Now, what I found on my pump is that there's noticeable wear on the shaft. I have to find a new sealing that has a slightly smaller diameter, the sealing itself is pretty odd sized so lets see if I can find a replacement. 

To be continued...