My  most "day-saving" repair was more mechanical and electrical than electronics-related. However, electronics take part in it too!

I own a 1990 VW Transporter. It is my precious weekend car, I converted it into a camper on my own. I do my best to have it prepared for any trip and to repair everything as soon as it shows signs of wear. I know every little bit of this car, because I've restored many parts of it, including some engine repairs, some metalwork and whole camping interior with solar panel, second battery, lights and power lines.

Last winter the V-belt, which is running the coolant pump and alternator got a little squeaky. However, I thought it's just cold because it never got noisy when the engine was hot. Then I've forgot about it. A few months later, in August, we were travelling across Poland for an old VW meetup. Somewhere in a middle of nowhere I noticed that my temperature gauge is slowly going down. It was a little worrying but hey - a little colder is better than too hot! I thought that maybe the thermostat broke and the weather is cold so the engine is cooling too fast. I pulled off to a gas station to fuel up the car and check if there are no leakages or other worrying signs. And... that was a permanent stop. I wasn't able to start the engine and drive away from the gas station! All lights were on on the dashboard as they should but the engine wasn't starting. At first I though - battery! But I thought this isn't possible as the battery was bought just a few months earlier (pandemic lockdown killed my previous battery). I pushed the car to a parking, unloaded all things from the space above the engine (engine in this VW is in the back and space above it is the main trunk of the car). I started looking for the problem. I didn't have my multimeter, just a probe with a light bulb. It seemed that there is voltage. I started looking through the wires...

I've spent 2 hours on the gas station, I've cleaned ALL contacts in the car - fuses, relays, ignition switch, dashboard connectors. I've replaced relays in the engine compartment. I've even replaced a few old wires in the engine compartment! I disassembled big part of the car electronics, including radio and cigarette lighter, because I suspected that there may be a short-circuit somewhere. And nothing.

In the end I tried to start the starter by connecting it directly to the battery. As soon as I've connected it, the light on my voltage probe went out and there was no action from the starter. I had the problem - the battery or the starter! I disassembled the battery and replaced with a second battery, which is far smaller and which I use to power basic loads while camping (diesel heater, phone charger, radio) but it is enough to start the engine. The engine started. I muffled a few very inappropriate words thinking about manufacturer of the dead battery. As I had the enigne compartment opened, I noticed that the V-belt is working somewhat strange... It was... wobbling (?) on the wheels. I stopped the engine and inspected the V-belt. This was a horror experience.

The V-belt was extremely damaged - missing many teeth, very stiff, the rubber was cracked in many places. I think that the only thing that kept it together was the fact that it was an original Gates belt with reinforcement inside...

As the belt was sliding during travel, the alternator wasn't working fast enough. However, the engine was warm and it wasn't squeaking. Old diesel engine has got huge power needs so the sliding V-belt wasn't providing enough power to keep the battery charged. After a few hours of such driving the battery got weak, when I turned the engine off at the gas station it didn't have enough power to start again. That's why the temperature gauge was dropping - it is thermoresistor based and dropping voltage seemed for the sensor as rising resistance of the sensor!

After 3.5 hours, with new battery and V-belt, nice amount of money poorer, I was able to continue my travel...

What did it learn to me? To replace the V-belt as soon as you hear a first squeak. It's not cold. Or maybe it is. It doesn't matter. It easier to replace a cheap V-belt when you have time for that that to replace it on a lonely gas station in a middle of nowhere. And this concerns not only mechanical issues - don't wait until something breaks. Replace as soon as it starts to behave strange! And never cross out first idea as ridiculous - if I didn't say that the battery is new and this couldn't be a problem with it, I would track down the problem in 20 minutes, not two hours! At least I have all contacts and relays cleaned!

Welcome fellow T3 owner!

I own a 1987 T3 which I've converted to TDi, they are great vehicles!

Welcome fellow T3 owner!

I own a 1987 T3 which I've converted to TDi, they are great vehicles!

I've got an original 1.7 diesel (KY)... With less original but far more functional interior - I've bought mine as a classic caravelle for 8 people.