Chevrolet G20 Starcraft Conversion Van, 1994
Discussion
Winter is coming and the temperature has dropped. Early mornings are becoming too cold for two wheels so I have been needing a winter beater vehicle.
The mustang is tucked away on a battery tender for the winter. I need a vehicle capable of moving and towing large equipment. Also something is very comfortable long distance, suitable for road trips, boondocking and camping in.
So I wanted something different, with multipurpose. I didn't want to splash out $50k on a loaded GMC Sierra and watch it depreciate as soon as it left the lot.
With a beater vehicle I did not want to spend more than $3k. I wanted something with classic Americana and parts must be common and cheap.
A friend at work picked himself an early 90s Dodge B250 Conversion Van converted by Mark3. I really liked the old skool American retroness, burgundy supercomfortable captains chairs, lashings of beechwood and a triple layout bed, high top roof, V8 and rwd, all for $1200.
Chevrolet, Dodge and Ford all have conversions available throughout the years from various companies on their vans.
All have their pros and cons but personally I wanted a GMC/Chevrolet G20/Vandura.
In my opinion they look the best of classic Americana. They were built from 1976-1995 and not much changed over the years. Abs, an airbag, that's pretty much it. They last a very long time, parts are very common and cheap, while GM trucks of the same era are practically the same platform and use the same car components. Even GM still produces parts.
The A team van was a short wheel base, cargo Vandura. The same van. Conversion vans are so cheap anyway I may aswell opt for one of those instead of getting a regular passenger/cargo van and adventurizing it.
I found one on craigslist that looked pretty nice. It was a 1994 Chevrolet G20 GT with a Starcraft Conversion.
Here are the Craigslist pics.
Roof rails, ladder, American Racing wheels, running boards and ground effects.
The later G20s had abs and ibs, which is an integrated belt system.
Electric mirrors and A pillar opening glass.
High top roof, front spoiler with integrated fogs.
V8 350 with a 4 bolt main. 4l80E transmission, 4 speed overdrive, RWD.
Triple electric foldout, slideable bed, full leather interior, Fold out table with drinks holders.
Surround sound, it has 2 stereo systems , front and rear, coat rack, storage space, in roof and rear doors.
Limo lighting.
Ashtrays and a host of 12v sockets everywhere. The middle seats are easy to remove and are also captains chairs.
Tv, VCR, antennas for radio, tv and Carphone.
Factory high end Ac delco radio cassette with equalizer! Every chair has padded armrests on both sides. Wood accents everywhere. Drivers seat is fully electric.
Electric windows and locks.
Column shifter. Hell yeah.
Hidden compartment with 12v that slides down for radar detector.
Since I can remember I loved the watching the A-Team. This was going to be so cool.
With dreams of rock and roll I went in search of the Chevy Van.
https://youtu.be/RiEIToOWr64
"I gave a girl a ride in my wagon,
she crawled in and took control.
She was tired, and her mind was dragging.
And I said get some sleep,
we'll get on down that road.
Like a picture, she was laying there,
moonlight dancing off her hair.
She woke up and took me by the hand.
She's gonna love me in my Chevy Van,
and that's alright with me.
Ya, her young face, was like that of an angel.
And her long leg's were tan and brown.
You better keep your eyes on that road, boy.
You better slow this vehicle down.
Cause like a picture, she was laying there,
moonlight dancing off her hair.
She woke up and took me by the hand.
She's gonna love me in my Chevy Van,
and that's alright with me.
Ya, I put her out in a town that was so small,
you could throw a rock from end to end.
A dirt road mainstreet,
She walked off in her barefeet.
And it's a shame I won't be passing that way again.
Cause like a picture, she was laying there,
moonlight dancing off her hair.
She woke up and took me by the hand.
We made love me in my Chevy Van,
and that's alright with me."
The mustang is tucked away on a battery tender for the winter. I need a vehicle capable of moving and towing large equipment. Also something is very comfortable long distance, suitable for road trips, boondocking and camping in.
So I wanted something different, with multipurpose. I didn't want to splash out $50k on a loaded GMC Sierra and watch it depreciate as soon as it left the lot.
With a beater vehicle I did not want to spend more than $3k. I wanted something with classic Americana and parts must be common and cheap.
A friend at work picked himself an early 90s Dodge B250 Conversion Van converted by Mark3. I really liked the old skool American retroness, burgundy supercomfortable captains chairs, lashings of beechwood and a triple layout bed, high top roof, V8 and rwd, all for $1200.
Chevrolet, Dodge and Ford all have conversions available throughout the years from various companies on their vans.
All have their pros and cons but personally I wanted a GMC/Chevrolet G20/Vandura.
In my opinion they look the best of classic Americana. They were built from 1976-1995 and not much changed over the years. Abs, an airbag, that's pretty much it. They last a very long time, parts are very common and cheap, while GM trucks of the same era are practically the same platform and use the same car components. Even GM still produces parts.
The A team van was a short wheel base, cargo Vandura. The same van. Conversion vans are so cheap anyway I may aswell opt for one of those instead of getting a regular passenger/cargo van and adventurizing it.
I found one on craigslist that looked pretty nice. It was a 1994 Chevrolet G20 GT with a Starcraft Conversion.
Here are the Craigslist pics.
Roof rails, ladder, American Racing wheels, running boards and ground effects.
The later G20s had abs and ibs, which is an integrated belt system.
Electric mirrors and A pillar opening glass.
High top roof, front spoiler with integrated fogs.
V8 350 with a 4 bolt main. 4l80E transmission, 4 speed overdrive, RWD.
Triple electric foldout, slideable bed, full leather interior, Fold out table with drinks holders.
Surround sound, it has 2 stereo systems , front and rear, coat rack, storage space, in roof and rear doors.
Limo lighting.
Ashtrays and a host of 12v sockets everywhere. The middle seats are easy to remove and are also captains chairs.
Tv, VCR, antennas for radio, tv and Carphone.
Factory high end Ac delco radio cassette with equalizer! Every chair has padded armrests on both sides. Wood accents everywhere. Drivers seat is fully electric.
Electric windows and locks.
Column shifter. Hell yeah.
Hidden compartment with 12v that slides down for radar detector.
Since I can remember I loved the watching the A-Team. This was going to be so cool.
With dreams of rock and roll I went in search of the Chevy Van.
https://youtu.be/RiEIToOWr64
"I gave a girl a ride in my wagon,
she crawled in and took control.
She was tired, and her mind was dragging.
And I said get some sleep,
we'll get on down that road.
Like a picture, she was laying there,
moonlight dancing off her hair.
She woke up and took me by the hand.
She's gonna love me in my Chevy Van,
and that's alright with me.
Ya, her young face, was like that of an angel.
And her long leg's were tan and brown.
You better keep your eyes on that road, boy.
You better slow this vehicle down.
Cause like a picture, she was laying there,
moonlight dancing off her hair.
She woke up and took me by the hand.
She's gonna love me in my Chevy Van,
and that's alright with me.
Ya, I put her out in a town that was so small,
you could throw a rock from end to end.
A dirt road mainstreet,
She walked off in her barefeet.
And it's a shame I won't be passing that way again.
Cause like a picture, she was laying there,
moonlight dancing off her hair.
She woke up and took me by the hand.
We made love me in my Chevy Van,
and that's alright with me."
Edited by 5ohmustang on Saturday 11th March 14:17
I think I've seen grand Voyager with pop up roofs.
There's an a team van replica on UK eBay,however it's incorrect in that it's a passenger van with Windows as opposed to a cargo panel van. Also the western wheels-turbines on it are too narrow.
http://m.ebay.co.uk/itm/GMC-DAYVAN-REPLICA-A-TEAM-...
It would be way cheaper to import one, they are dirt cheap in the U.S. as vans are not that popular anymore.
No cowboy hats are required, that's the previous owners btw. However moustaches and bruit aftershave is mandatory.
There's an a team van replica on UK eBay,however it's incorrect in that it's a passenger van with Windows as opposed to a cargo panel van. Also the western wheels-turbines on it are too narrow.
http://m.ebay.co.uk/itm/GMC-DAYVAN-REPLICA-A-TEAM-...
It would be way cheaper to import one, they are dirt cheap in the U.S. as vans are not that popular anymore.
No cowboy hats are required, that's the previous owners btw. However moustaches and bruit aftershave is mandatory.
We went to look at the van in a mountain valley in middle Tennessee. The owner had hit a kerb and smashed the lower front spoiler plus destroying the wheel.
I knocked $500 of the price. Overall it is ok.
The initial issues it has:
Broken front spoiler
Missing one of the wheels
Heater air does not come of windshield demisting
Couple of rust spots
Brake booster and master cylinder is leaking
We took it for a test drive and surprising the V8 has plenty of torque, in a straight line it is brisk.
When it got to the corners, it handled just as you would expect, wallowing and rolling. I'd bet the shocks and struts are the original ones. The transmission shifts very smooth
So I bought the van for $2500.
Registered it, put on a license plate on it and road tax, total was $70. Next year it should be around $30 for tax.
Insurance is $10 a month.
Petrol is 1.77 a gallon and has a 33 gallon tank.
It is very comfortable to drive. We stopped at Taco Bell and ate in the back. No more eating inside. The tv and VCR work and uses the middle speakers. The stereo operates front and rear speakers but front speakers are blown.
More info to come.
I knocked $500 of the price. Overall it is ok.
The initial issues it has:
Broken front spoiler
Missing one of the wheels
Heater air does not come of windshield demisting
Couple of rust spots
Brake booster and master cylinder is leaking
We took it for a test drive and surprising the V8 has plenty of torque, in a straight line it is brisk.
When it got to the corners, it handled just as you would expect, wallowing and rolling. I'd bet the shocks and struts are the original ones. The transmission shifts very smooth
So I bought the van for $2500.
Registered it, put on a license plate on it and road tax, total was $70. Next year it should be around $30 for tax.
Insurance is $10 a month.
Petrol is 1.77 a gallon and has a 33 gallon tank.
It is very comfortable to drive. We stopped at Taco Bell and ate in the back. No more eating inside. The tv and VCR work and uses the middle speakers. The stereo operates front and rear speakers but front speakers are blown.
More info to come.
Wow that looks in mint condition. How much do they go for in the UK?
The best I have got is 15.5 US mpg so around 19 UK mpg. That was with uneven tires, no tune up and I didn't realize square D was overdrive. Regular D is 3 speed and locks out the 4th overdrive gear.
The front door interior panels need to be rebuilt, it's more time consuming than difficult.
I've been getting a wind rushing noise on the lower left A pillar when the window is up on the highway. Part of the door seal has dry rot so I bought 2 new door seals for $40.
However they are a pain in the ass to remove cleanly without leaving stuck on old rubber. While doing this, I noticed a random lever near the parking brake. It opens and closes a flap under the dash. I think that was where the wind noise was coming. What it is there for I do not know.
It's easy to remove the middle captains chairs, however they're pretty heavy. The rear seats/electric bed works. We added a mattress topper and went camping. It was seriously comfortable.
However there's a parasitic drain somewhere. It has this thing called a Battery Buddy that acts as a circuit breaker when the battery gets too low. It has a reset button that you need to press to turn the circuit back on (located under the bonnet) while someone else cranks the key. It saved the battery a few times but something is draining the battery eitherway.
I did have the battery checked and it was showing bad so that was replaced.
I believe the problem lies with the original but aftermarket alarm system. That's my next task.
Here are the new wheels. I mounted one of the back ones on the front to see how wide it would look. It may clear but i'll settle for 15x8.
The best I have got is 15.5 US mpg so around 19 UK mpg. That was with uneven tires, no tune up and I didn't realize square D was overdrive. Regular D is 3 speed and locks out the 4th overdrive gear.
The front door interior panels need to be rebuilt, it's more time consuming than difficult.
I've been getting a wind rushing noise on the lower left A pillar when the window is up on the highway. Part of the door seal has dry rot so I bought 2 new door seals for $40.
However they are a pain in the ass to remove cleanly without leaving stuck on old rubber. While doing this, I noticed a random lever near the parking brake. It opens and closes a flap under the dash. I think that was where the wind noise was coming. What it is there for I do not know.
It's easy to remove the middle captains chairs, however they're pretty heavy. The rear seats/electric bed works. We added a mattress topper and went camping. It was seriously comfortable.
However there's a parasitic drain somewhere. It has this thing called a Battery Buddy that acts as a circuit breaker when the battery gets too low. It has a reset button that you need to press to turn the circuit back on (located under the bonnet) while someone else cranks the key. It saved the battery a few times but something is draining the battery eitherway.
I did have the battery checked and it was showing bad so that was replaced.
I believe the problem lies with the original but aftermarket alarm system. That's my next task.
Here are the new wheels. I mounted one of the back ones on the front to see how wide it would look. It may clear but i'll settle for 15x8.
Edited by 5ohmustang on Wednesday 23 November 17:27
Lugy said:
These are a bit of a guilty pleasure of mine, a mate bought a '97 though with the lesser V6 engine, he's been away a couple of times with it and seems to enjoy all the same. I found it quite humorous when he said he was varnishing his interior one day
.On these older vans like the g20/vandura the main companies that did 4wd van conversions were Pathfinder and Quigley. Quigley still exist today and make some really cool vans.
Here's a Pathfinder.
The g20 is the medium duty van. The g10 was the light duty and g30 was the heavy duty version.
Engine options were the 4.3 v6 vortec, 5.0 v8, 5.7 v8, 6.2 v8 diesel and the 454 big block.
Here is a GMC Savanna RoadTrek class B with a Quigley conversion.
4wd vans in the states are rare and usually fetch a premium unless it's a fixer upper.
Rumbleofthunder It's an been years since I've watched Alan Partridge so I don't remember who Tex is, YouTube is not bringing up any hits.
Shaker maker, I bet it would be a lot cheaper than a hotel plus you're not stuck in one place.
I want to drive route 66 in it's entirety soon. The roof rails were loose and the old gaskets were perished. I used clear RTV and rescrewed the rails down. I don't want to put a roof basket on there in case the roof is overloaded and cracks. Walmart sell waterproof roof bags that cinch to the rails. I'll probably keep cloths up there to keep it light.
This g20 does not have the tow package so at some point I'll get a class IV trailer hitch and get a basket for travelling.
I also want a motorcycle carrier. It looks kind of dodgy having a 500lb bike suspended 2ft away from the actual hitch, especially on bumpy roads.
OpulentBob. It is a pleasure to drive as long as you're not in a hurry. Initially off the line it's slow, once the momentum is going it picks up fast, lots of midrange. It's just that brief moment moving from stationary. I've had it beyond 85 and into the black.
The 4 speed auto transmission with overdrive does what it needs to do to get the job done. The shifts are smooth and it is kind of nice not having to change gears. I believe the gearbox is a 4l80e which is the same as many other gm trucks. It should be the same as a gift (old military Chevy blazer/c10 truck and the humvee). Which more than likely does not have a drain plug. It's a messy job as you have to navigate the transmission pan with old fluid around the exhaust missile and not spill it.
Brakes are ok, discs front, drums rear with abs. At slow speeds I could hear a metallic whine. I believe it was the left brake drum, rubbing on the shoes that were out of adjustment.
I don't like working on drums but once you get the general concept it's not too bad. There is a adjustment cog on the bottom that either expands or contracts the brake shoes.
Took a drill with a wire brush attachment and cleaned off the surface rust on the drums.
The suspension though is very soft, comfy, however around corners you better hang on. I hope it's just down to being old worn out shocks and springs. All the ball joints are blown, I am piecing all the steering components at the moment.
Being a 350 it has a lot of cheap tuning potential but this is an adventure van, not a race van. So anything I can do to improve mpg and reliability the better.
Thanks Jimmy.
LeighW that safari is seriously cool. Apparently the Astro/safari has a cult following in Japan. They're usually the cleanest.
That high top roof has overhead popout sunroofs, really nice.
I was originally looking for an astro/safari and I may still get one. They're very common and dirt cheap. However I want an AWD version. You would not think but in the snow they are unstoppable. In the south there harder to find but they're out there.
When I lived in Colorado they were everywhere. As well as VW Canyons and Westfalias. 90% of U.S. Westfalias are in Colorado.
I did want a Westfalia but it is much easier to find parts for ford, dodge and Chevy vans. Also American vans are much more luxurious. The Astro/safari to get is not just the awd but a conversion too, rather than the regular passenger van. I found one for sale recently for $3300 but mine has more interior space.
F1nn want some candy?
There are tons of conversion vans on US eBay. Typically listed as under the van model e150, e250, e350, g10, g20, g30, b250, b350. I reckon the cheapest way to get one is a Japanese import.
I've found craigslist is usually cheaper than eBay. I use www.searchtempest.com to search over multiple craigslist locations.
Shaker maker, I bet it would be a lot cheaper than a hotel plus you're not stuck in one place.
I want to drive route 66 in it's entirety soon. The roof rails were loose and the old gaskets were perished. I used clear RTV and rescrewed the rails down. I don't want to put a roof basket on there in case the roof is overloaded and cracks. Walmart sell waterproof roof bags that cinch to the rails. I'll probably keep cloths up there to keep it light.
This g20 does not have the tow package so at some point I'll get a class IV trailer hitch and get a basket for travelling.
I also want a motorcycle carrier. It looks kind of dodgy having a 500lb bike suspended 2ft away from the actual hitch, especially on bumpy roads.
OpulentBob. It is a pleasure to drive as long as you're not in a hurry. Initially off the line it's slow, once the momentum is going it picks up fast, lots of midrange. It's just that brief moment moving from stationary. I've had it beyond 85 and into the black.
The 4 speed auto transmission with overdrive does what it needs to do to get the job done. The shifts are smooth and it is kind of nice not having to change gears. I believe the gearbox is a 4l80e which is the same as many other gm trucks. It should be the same as a gift (old military Chevy blazer/c10 truck and the humvee). Which more than likely does not have a drain plug. It's a messy job as you have to navigate the transmission pan with old fluid around the exhaust missile and not spill it.
Brakes are ok, discs front, drums rear with abs. At slow speeds I could hear a metallic whine. I believe it was the left brake drum, rubbing on the shoes that were out of adjustment.
I don't like working on drums but once you get the general concept it's not too bad. There is a adjustment cog on the bottom that either expands or contracts the brake shoes.
Took a drill with a wire brush attachment and cleaned off the surface rust on the drums.
The suspension though is very soft, comfy, however around corners you better hang on. I hope it's just down to being old worn out shocks and springs. All the ball joints are blown, I am piecing all the steering components at the moment.
Being a 350 it has a lot of cheap tuning potential but this is an adventure van, not a race van. So anything I can do to improve mpg and reliability the better.
Thanks Jimmy.
LeighW that safari is seriously cool. Apparently the Astro/safari has a cult following in Japan. They're usually the cleanest.
That high top roof has overhead popout sunroofs, really nice.
I was originally looking for an astro/safari and I may still get one. They're very common and dirt cheap. However I want an AWD version. You would not think but in the snow they are unstoppable. In the south there harder to find but they're out there.
When I lived in Colorado they were everywhere. As well as VW Canyons and Westfalias. 90% of U.S. Westfalias are in Colorado.
I did want a Westfalia but it is much easier to find parts for ford, dodge and Chevy vans. Also American vans are much more luxurious. The Astro/safari to get is not just the awd but a conversion too, rather than the regular passenger van. I found one for sale recently for $3300 but mine has more interior space.
F1nn want some candy?
There are tons of conversion vans on US eBay. Typically listed as under the van model e150, e250, e350, g10, g20, g30, b250, b350. I reckon the cheapest way to get one is a Japanese import.
I've found craigslist is usually cheaper than eBay. I use www.searchtempest.com to search over multiple craigslist locations.
Now this is a van.
E350 dually, with a Quigley 4wd conversion, with the 7.3 power stroke international engine
http://m.ebay.com/itm/1998-Ford-E-Series-Van-/3519...
Did they ever make 4wd transit vans?
I remember dually transit vans back in the 80s.
European vans are replacing the U.S. vans nowadays, however they seem to be much more expensive.
E350 dually, with a Quigley 4wd conversion, with the 7.3 power stroke international engine
http://m.ebay.com/itm/1998-Ford-E-Series-Van-/3519...
Did they ever make 4wd transit vans?
I remember dually transit vans back in the 80s.
European vans are replacing the U.S. vans nowadays, however they seem to be much more expensive.
Shakermaker said:
Tex was a friend of Michael from the Petrol station. He loved American things like monster trucks, and used the plural term 'convoy' to describe a single vehicle.
He liked monster trucks too.
It's in one episode, where Alan wants to watch all the James Bond moves over the bank holiday weekend.
Haha yes I'm that guy.He liked monster trucks too.
It's in one episode, where Alan wants to watch all the James Bond moves over the bank holiday weekend.
There's a few conversion vans on UK eBay with lpg conversions.
I found this astro awd conversion with the DIGITAL DASH! The digital dash was a rare option on the 2nd generation astro/Safari vans.
http://m.ebay.co.uk/itm/Chevrolet-Astro-GMC-Van-4-...
http://m.ebay.co.uk/itm/FRESH-IMPORT-2000-W-REG-CH...
http://m.ebay.co.uk/itm/CHEVROLET-ASTRO-GMC-SAFARI...
http://m.ebay.co.uk/itm/CHEVROLET-ASTRO-DAY-VAN-ON...
I found this astro awd conversion with the DIGITAL DASH! The digital dash was a rare option on the 2nd generation astro/Safari vans.
http://m.ebay.co.uk/itm/Chevrolet-Astro-GMC-Van-4-...
http://m.ebay.co.uk/itm/FRESH-IMPORT-2000-W-REG-CH...
http://m.ebay.co.uk/itm/CHEVROLET-ASTRO-GMC-SAFARI...
http://m.ebay.co.uk/itm/CHEVROLET-ASTRO-DAY-VAN-ON...
OpulentBob said:
Do any come with a small kitchen conversion, or is that going too far for a "day van"? Somewhere to boil a kettle or prepare a (basic) meal would mean this is a good, left field alternative to something like a VW camper, IMO. Broadly similar running costs, I expect, and I would guess more reliability to boot.
Yes you correct. As a conversion van they were not supposed to have camper equipment. It has been done by owners by times though. Plus you could always tow a small pull behind travel trailer/camper.
The same vans were sold as camper vans however and fall under the label "class B camper van."
LeighW said:
Mine had a removable sink unit, but I bought an awning and used that for camping. I also fitted a mains hook up. The running costs weren't too bad, the main expense was fuel as it only managed about 21-22mpg on a run, and less around town. In the end I sold mine and bought a T5 as I was bored of faffing around putting up and taking down the awning every time we wanted to move on. The T5 manages high thirties to the gallon, which when we're doing a 1400 mile tour around the Highlands makes a difference. That said, the T5 owes be about £12k, and the Safari cost a whole lot less. The Safari was really comfy to drive as well, think your favourite armchair with cruise control! 
That is bloody nice. Where did you mount the awning to. I want one but I am a bit worried about drilling into the high top roof. 
LeighW said:
Mine had a removable sink unit, but I bought an awning and used that for camping. I also fitted a mains hook up. The running costs weren't too bad, the main expense was fuel as it only managed about 21-22mpg on a run, and less around town. In the end I sold mine and bought a T5 as I was bored of faffing around putting up and taking down the awning every time we wanted to move on. The T5 manages high thirties to the gallon, which when we're doing a 1400 mile tour around the Highlands makes a difference. That said, the T5 owes be about £12k, and the Safari cost a whole lot less. The Safari was really comfy to drive as well, think your favourite armchair with cruise control!
That is bloody nice. Where did you mount the awning to. I want one but I am a bit worried about drilling into the high top roof. Morningside said:
I am loving it and would love one myself. But 1990s? With all that wood it looks more 1970s in there.
All it needs to finish it off is a disco ball and an eight track player!
1970s was shag carpet and tolken murals. It is very 1980s and that's why I like it. The express and savanna vans have more modern interiors. However I am stuck in the 1980's my wife will tell you that too.All it needs to finish it off is a disco ball and an eight track player!
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Time for an update. Not to long after my last post I needed to move furniture to my other house. There are 6 bolts holding the bed/sofa down. 23 years of crap and rust on the bolts made it a very long job. It is a 2 person job. When the bed goes back in I will replace the bolts. It is heavy as are the captains chairs.
The van was having difficulty starting. It would turn but not fire up.
It was late at night, I was driving my wife's car and she was in the van. I stopped at a gas station to fill up the car. My wife turned off the van, when it came to turning it back on, it would turn and not start.
Eventually the battery died from repetitive cranking.
I normally keep jump cables in the trunk of my wife's car. Well I forget them at the house. I picked up a set from Walmart and charged up the van for 20 minutes, it still would not start. I believe it was an electrical issue caused by the original aftermarket 90s alarm system. I started messing around with some of the wires and it automatically locked the van and triggered the alarm, for which the owner had lost the key fob.
Luckily I had opened the rear door to get my tools out. So after climbing a sea of furniture I got to the front door and unlocked the van.
Eventually I got the van the start. I drove it to my other house and once running it was fine.
So the plan was to do all the basic maintenance on the van after work. The problem is that it's really cold and dark, which is the reason for the lack of photos here.
Firstly I removed the alarm system from the van. The schematics were included with the papers for the van so I just traced the wires, found the shock sensor, control unit and relay. Cut out the splices and rejoined the wires and heat shrinked.
I then began on removing the dog house. What should have been a simple task is a hassle due to the extra conversion parts. So there are 2 layer of wood and plastics. The switches for the electric mirrors and interior limo lighting are easy to damage if you pull on the wood too much.
So I replaced the air filter, coolant temp sensor, pcv valve, pcv valve pipe. Then came the spark plugs, well the passenger side rear spark plug sheered off. The whole hexagon part. There is no room to use a drill and an easy out due to the floor. I tried using wd40, pb blaster, freeze out, nothing worked. I tried vice grips with a crescent wrench (adjustable spanner). Still did not move.
It's too dark and cold to remove the head myself so I called a garage to get a quote. $1250. No way in hell was I paying half the value of the van to remove the head to have the spark plug removed.
I ended buying an Irwin bolt extractor kit from Lowes for $20. Combined with a breaker bar I removed the spark plug in 30 seconds. I then replaced the spark plugs, spark plug leads, rotor arm, dizzy cap.
When I tried to remove the broken spark plug, in order to get access I had to remove the exhaust manifold. Well there were no gaskets, so I added some.
Plus where the manifold meets the clamp/flange, I had sheered off one of the studs. I had to remove it completely and drill out the broken bolt. I replaced all the studs and manifold bolts.
Once everything was back together it still would not fire up. Eventually I got it running, drove it to autozone to get an output shaft seal as that was leaking tranny fluid. All of a sudden there is a clicking sound that frequency changed as rpm's increased, figured out the exhaust manifold has a leak.
So then the van would not start at autozone. I turned the key 7 times to see if priming the fuel pump would work. Well it did. I started driving it home, then it cuts out totally, power steering turns off, and coasted to a stop at a Mcdonalds.
Then it fired up. Got home. It had to be fuel related. I had a fuel filter, replaced it, still did not effect anything. Then its either the fuel pump relay or the fuel pump. I picked up a new relay, swapped it out and now it runs no problem.
Next I dropped the driveshaft to get to the output shaft seal. Removed the 4 bolts on the drive shaft, pulled out the yoke. The drive shaft is a beast, surprisingly it is aluminum and was light.
I had to get a special tool to pull out the seal. The seal kit comes with a bushing that goes in the transmission tailhouse. Well there was no way I could pull it out. It was too risky gouging the output shaft. I then unplugged the transmission harness, removed 4 bolts, the housing came off.
I took it to a friend with a 75 ton press to remove the old seal and refit the new seal. The drive shaft is now back in.
What I have learned is, from the factory these manifolds never came with gaskets, hence the clicking sound. I managed to undo the manifold bolts, and slid the gaskets out. My next step is to install the manifolds.
The van was having difficulty starting. It would turn but not fire up.
It was late at night, I was driving my wife's car and she was in the van. I stopped at a gas station to fill up the car. My wife turned off the van, when it came to turning it back on, it would turn and not start.
Eventually the battery died from repetitive cranking.
I normally keep jump cables in the trunk of my wife's car. Well I forget them at the house. I picked up a set from Walmart and charged up the van for 20 minutes, it still would not start. I believe it was an electrical issue caused by the original aftermarket 90s alarm system. I started messing around with some of the wires and it automatically locked the van and triggered the alarm, for which the owner had lost the key fob.
Luckily I had opened the rear door to get my tools out. So after climbing a sea of furniture I got to the front door and unlocked the van.
Eventually I got the van the start. I drove it to my other house and once running it was fine.
So the plan was to do all the basic maintenance on the van after work. The problem is that it's really cold and dark, which is the reason for the lack of photos here.
Firstly I removed the alarm system from the van. The schematics were included with the papers for the van so I just traced the wires, found the shock sensor, control unit and relay. Cut out the splices and rejoined the wires and heat shrinked.
I then began on removing the dog house. What should have been a simple task is a hassle due to the extra conversion parts. So there are 2 layer of wood and plastics. The switches for the electric mirrors and interior limo lighting are easy to damage if you pull on the wood too much.
So I replaced the air filter, coolant temp sensor, pcv valve, pcv valve pipe. Then came the spark plugs, well the passenger side rear spark plug sheered off. The whole hexagon part. There is no room to use a drill and an easy out due to the floor. I tried using wd40, pb blaster, freeze out, nothing worked. I tried vice grips with a crescent wrench (adjustable spanner). Still did not move.
It's too dark and cold to remove the head myself so I called a garage to get a quote. $1250. No way in hell was I paying half the value of the van to remove the head to have the spark plug removed.
I ended buying an Irwin bolt extractor kit from Lowes for $20. Combined with a breaker bar I removed the spark plug in 30 seconds. I then replaced the spark plugs, spark plug leads, rotor arm, dizzy cap.
When I tried to remove the broken spark plug, in order to get access I had to remove the exhaust manifold. Well there were no gaskets, so I added some.
Plus where the manifold meets the clamp/flange, I had sheered off one of the studs. I had to remove it completely and drill out the broken bolt. I replaced all the studs and manifold bolts.
Once everything was back together it still would not fire up. Eventually I got it running, drove it to autozone to get an output shaft seal as that was leaking tranny fluid. All of a sudden there is a clicking sound that frequency changed as rpm's increased, figured out the exhaust manifold has a leak.
So then the van would not start at autozone. I turned the key 7 times to see if priming the fuel pump would work. Well it did. I started driving it home, then it cuts out totally, power steering turns off, and coasted to a stop at a Mcdonalds.
Then it fired up. Got home. It had to be fuel related. I had a fuel filter, replaced it, still did not effect anything. Then its either the fuel pump relay or the fuel pump. I picked up a new relay, swapped it out and now it runs no problem.
Next I dropped the driveshaft to get to the output shaft seal. Removed the 4 bolts on the drive shaft, pulled out the yoke. The drive shaft is a beast, surprisingly it is aluminum and was light.
I had to get a special tool to pull out the seal. The seal kit comes with a bushing that goes in the transmission tailhouse. Well there was no way I could pull it out. It was too risky gouging the output shaft. I then unplugged the transmission harness, removed 4 bolts, the housing came off.
I took it to a friend with a 75 ton press to remove the old seal and refit the new seal. The drive shaft is now back in.
What I have learned is, from the factory these manifolds never came with gaskets, hence the clicking sound. I managed to undo the manifold bolts, and slid the gaskets out. My next step is to install the manifolds.
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