Category Archives: VW Amarok

How’ve We Been Getting On With Our Catch Can?

09 Thursday May 2019

Posted by in Amarok, General, Maintenance, Modifications, tow vehicle, VW Amarok

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Back in June 2018 I fitted a Man Hummel ProVent oil catch can to our Amarok. Since then I’ve had a few people asking me how we have been getting on with it and has it actually ‘caught’ anything.

If you haven’t a clue what I’m on about here’s a link to the original two posts…. Catch Me If You Can… and Catch Me If You Can Pt 2

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I fitted the ProVent to our VW Amarok when it had done about 8000 miles (12,800Km) and we have now done just over 13,000 miles (21,000Km) a great deal of it towing. I opted initially to drain the ProVent every 600 Miles (1000Km) and the first three each time I got about half a cup of slightly oily water. It was clear like water but when rubbed between your fingers it felt ‘slippy’ a bit like baby oil. I did notice that one    draining that covered two long tows up to the Lake District what came out was slightly darker, still about the same quantity though. However I did notice on the last draining I had more of a dark oil content as a separate layer in the lighter clear ‘oily water’. Watching the video below I did find out that this is normal. The filter that is in the ProVent takes a few hundred Km to start working properly, first catching the condensate and then once the filter is saturated does it start to catch and drain the heavy oil.

I did recently remove the hoses on the intercooler (inlet and outlet) just out of curiosity and the interior from what I could see was still clean, with only a light covering deposited from the first 8000 miles (13,000Km) of running without a catch can fitted.

So how much have I got out?

Well in the first 5000 miles (8000Km) I have now filled an old 500ml  2 stroke oil container and just started on my second. I’ll continue to drain at the 600 mile mark. Although I must admit I now drain it before a long towing trip and again when I return home. It only takes about a minute and doesn’t require any tools so really is one of those tasks that is easily accomplished with the minimal of effort. Hopefully this will keep our engine in tip-top condition and not start to suffer from the oily carbon build up that saps power and is prevalent in all diesel engines.

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Here’s an excellent video from the guy’s at 4WD Action with probably the best explanation I’ve seen so far on the net… (Video (c) 4WDAction.AU)

Setting Up the Garmin Camper 770 LMT-D…

04 Saturday May 2019

Posted by in Gadgets, GPS, Navigation, Sat Nav, VW Amarok

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Following on from my issues with our TomTom (Why I’m ditching TomTom and moving to Garmin… ) our new Sat Nav arrived a few days ago. I did look a the Snooper option, but there were a few limitations that I personally wasn’t comfortable with, but overall it looked a good product. I have had some great feedback from users of the Snooper and the company seems to have a really good customer service department.

I ordered our Garmin Camper 770LMT-D from Amazon ( https://amzn.to/2Vca1j4 ) for £256 and opted to add a SanDisk Extream 32GB microSDHC Memory Card (https://amzn.to/2Jem1JK ) for £10 which should give me flexibility in the future. That said, the internal memory on the 770 is already quite big at 15Gb.

Before the unit arrived, I downloaded Garmin Basecamp – there are downloads available for both Windows and Mac platforms. I also downloaded Garmin Express. Installing on a Mac was straight forward as usual. I can’t comment on the Windows version as we have not owned a Microsoft platformed device for over 13 years.

While writing this I found out what the LMT-D stands for… LMT is Lifetime Maps & Traffic and the D is DAB Radio reception.. it receives traffic updated via the inbuilt DAB radio receiver. No it can’t play DAB radio stations before you ask.

Garmin Basecamp

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When you first install Basecamp is comes with a default Global Map….

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It is not until you connect your GPS and download the updated map from it does it have all the fine detail and pre installed POI’s.

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I have zoomed in to Holyhead here….

All the pre installed POI’s from the GPS show up and it makes it easy to have a mooch round the area from your desk when planning a route. I’m not going to go into too much detail about setting up your own POI’s (although they are really waypoints in Garmin’s world) or setting up Routs, tracks etc. I did find it really easy to follow Garmin’s on line video tutorial. However it took me a couple of go’s to get the information I wanted in the right fields.

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Here I set up a waypoint for Southport C & M Club. Really easy and only took less than a minute. By installing Garmin Basecamp before actually receiving the 770, it gave me a chance to sit and play about with the software before getting too distracted by the new gadget. I set up about 50 waypoints, sorting them into various categories – C & M Club, Museums, Ports, Friends etc. As I was unsure what actually came pre-installed I thought it might be best to get a head start on the most common ones.

What’s installed on the Camper 770?

Really I need not have bothered too much. The Garmin Camper 770 comes with ASCI, MHF, Campercontact as well as Trip Advisor & Foursquare databases already pre-installed. As it connects to WiFi and via a phone App to the internet, you can pretty much search for any location or attraction. I’ve set ours up so it connects to the Amarok’s WiFi system for permanent internet access. You can also install Archie’s database too if you think that you need all the bases covering.

First Job – Update the 770

First job was to update the Garmin 770 with the latest maps and databases. To do this you need to install Garmin Express. Once installed, simply connect the GPS with the supplied USB lead and follow the on screen prompts. To get to the point where it starts to update only took a minute or two… inputting an email address really and naming the unit so if you have multiple Garmin products you can easily identify which GPS you have connected. It estimated that it would take around 2 hours to perform the download and all the updates, in reality it took less than 30 minutes.

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Setting up the vehicle and vehicle options came next. Again really simple to do. I found the menu system is quite simple to navigate through, and it didn’t take too long to set up our rig…

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You may notice the “80” Kmh sign in the top right corner. As you can input the weights of the vehicle, caravan, motorhome into the unit. It will keep an eye on the speed limits on roads. In europe where a lot of countries have lower limits for vehicles or towing combinations above certain weights…. France for example has a 3.5t cut off, above this weight and you have a lower speed limit that say a car and caravan under 3.5t on the same road. I’m sure motorhome owners who regularly travel in Europe will be more aware of these rules.

I could have got away with just the standard CAR setup for the Amarok when not towing, but as the Amarok has a body width of  1954mm (6’5″) and maximum of mirror to mirror with of 2228mm (7’3.5″) (5321mm or 17’5.5″ long if you are playing top trumps!) sometimes on a couple of width restricted roads I have had to really squeeze through, so I thought I’d set up a motorhome setting with the Amarok’s size just so I wouldn’t get caught out. And yes… that weight is correct. The MTPLM of the caravan and MPM of the  Amarok totals 4770 Kgs and there are a couple of  bridges in the UK I can’t legally tow over!

The Installation…

I’m a bit of a…. well I don’t know, when it comes to getting things right. I sat in the truck and moved the 770 around… placing it almost everywhere. I wanted it so it could be reached from either the driver or passenger seats, but not too close as it might fall into that focal length area where it’s just outside the range of either part of my bi-focal’s. I wasn’t happy with all the options available. So I thought tomorrow might bring inspiration. However all tomorrow brought was the same ‘Umm….” and “Nope…..”. The third day however did bring fourth a result….

I still wanted access to the top tray, but placing the GPS on the windscreen with the suppled mount was not an option. One, I hate things stuck to the windscreen and two, neither Sue or I could reach the screen from our normal seating position. So off to the bat cave to come up with a cunning contrivance. Half an hour later after shaping and bending some 1.5mm thick aircraft aluminium and a quick application of anti glare black… (I also followed that up with some anti glare cloth tape we used in aircraft cockpits)

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It still uses the Garmin quick release mount and has the flexibility to adjust fully either way and tilt down to minimise glare if the sun is reflecting directly on it (the screen is super bright though max and hopefully this won’t be a problem). We can both still reach it and the tray in front as well as being fully accessible is a convenient place to wrest your wrist while inputting info into the GPS. I have found though the Voice Command understands a “Manc” accent really well and i haven’t had any issues using voice command.

What I like…

I do like Basecamp. I’ve found out that I can overlay OS Landranger maps which makes plotting very accurate walking routes and printing them out easy. I can also create accurate Green Lane routes for off road 4 x 4 treks and import them into the 770. You can also convert Google Map routing and import it into Basecamp and your GPS. Now this is really useful. For example… setting off from Manchester about 04:00 going to Dover to catch the 10:00 ferry sailing, however I need to fill with LPG en route. I set my departure point, arrival point and search for LPG closest to my route. I can then pick one see the estimated arrival time at that point (check that the LPG station is open) and adjust my route to take in the LPG waypoint or choose the next LPG station if I am going to arrive too early.  This can then be uploaded to the 770 as a route and will adjust around traffic still directing you first to the LPG station then to your destination.

Within Basecamp you have an option to upload your waypoints to either the 770’s internal memory or the Memory Card. You can also update the memory card by removing it from the 770 and connecting it directly to your desktop device. I’ve chosen to install all my info on to the memory card rather than the 770’s internal memory… did I really need a memory card? At this point probably not but it has allowed me a bit more flexibility and when I ordered the 770 I didn’t know just how much space I’d be left with, at the moment I’ve used about 10Gb of the 15Gb internal memory. You do have the option to install additional maps on to the memory card, so for example if I wanted North America I could install it onto the removable card. There is security built in to stop maps downloaded on one device being transferred to another device.

I found the updating of the 770 using Garmin Express to be really easy too. I have been checking it every day so far just to get a fell of how often the updates come through. So far I’ve had three updates after my initial first download. I tend to suspect that maybe Garmin have a more frequent update policy, which could be a reflection of the aviation side of the business where updates are tightly scheduled and frequent to reflect any airspace and NOTAM updates. I did note that one or two things and functions in route planning within Basecamp seemed strangely familiar… until it clicked…. I’d seen and used them before in flight planning applications.

There is a couple of other features that I’ve not had before. The Garmin 770 records all your tracks… now this is really handy so when Sue say’s “Do you remember we passed such and such the other day… can we go back?” Well, I can usually remember the vague details… but being able to bring up the route we drove and doing a bit of investigation using Garmin Basecamps opens up the possibility of being able to find it again without having to resort to a darkened room, angle poise light and an impression of Herr Flick.

The other is the ability take a snapshot of the screen. I used it for a few screen shots ( like the one above showing the vehicle set up) and a few I’ve taken for a full review. I don’t know if this is a ‘feature’ that is not really a feature as it’s noever gets used…. or if it’s something I might use in the future. Might be handy for quick maps of trips or places, there again it might not. Jury’s out on that one.

I’m not able to give a full review… as we haven’t been anywhere with it yet so I can’t comment on traffic updates, turn by turn instructions, general usability or function. we are off in the next few days for five days so I’ll let you know how we get on.

… and for all those pilots out there the classic ATC…. “Resume own navigation”

Mirror Mirror…

15 Monday Apr 2019

Posted by in Accessories, Amarok, General, Modifications, Projects, VW Amarok

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A couple of eagle-eyed mirror aficionados have spotted that we use Milenco Grand Aero 3 towing mirrors… but they also spotted that there was something different about the mounts. OK I’ll have to admit you are an eagle eyed bunch!

On the Amarok, the mirrors are quite big and if I get them adjusted about right I can just see down both sides of the caravan… we’re not 8 foot wide. However, driving without mirrors is more likely to attract attention and it’s easier and safer just to fit a pair. I first went for a brand that I’d used on the Land Rover Freelander, however the Amarok’s mirrors are quite deep and it wasn’t till I tried them that I realised how much of an issue that was….

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The other issue I had… I didn’t particularly like the fitting….. it was about on the limits of extension and about 25% of the mirror was obscured by the Amarok’s door mirror… just at the point the would allow you to see the wheels of the caravan. Not ideal.

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So I looked round for a mirror that would move the face of the mirror rearwards in about the same plane as the normal Amarok mirror. The added depth of the Milenco Grand Aero looked as though it would do the job perfectly.

Actually it was a little too much. As the mounting for the mirror was now on the door mirror plane, not as the previous mirror the back of the mirror housing it shifted the face of the Grand Aero too far rearwards. I liked the vision the Grand Aero gave and the mounting.

To the Bat Cave…

I just happened to have some lengths of 12mm steel tubing and a bending tool. Maybe I could solve the problem without searching round for other products.

I used a welding rod to hand bend a profile that seemed to put the mirror into the right position. I worked out I’d only need two bends to get the mirror in the right position.

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I installed the two mounting brackets on the door mirror in the final position I wanted them and slid a length of tube into them. Marking where I wanted the first bend to be and using an angle finder to approximate the angle that would move the mirror far enough forward so the face was in line with the door mirror face… this then gave me the point to start the bend upwards to get the mirror at the correct height.

Ok before I get a lot of comments asking why installed the mounts on the lower edge of the mirror… two reasons…. if they do move about or squish down on a bit of grit any scratches won’t be seen in the painted area of the door mirrors and from the driving position they don’t obscure my view if I have to look past the top of the door mirrors. I’ve also noticed when its raining I don’t get nearly as much water running down the face of the door mirror. And another reason…. the bottom of the door mirror on the Amarok is not quite as curved and the clamps fitted more securely. I’ve got everything dialed in now to the point where I don’t actually need to adjust the mirrors each time I fit them.

At this point I hadn’t cut the tube to length on the vertical section so I had the chance to adjust the height of the Grand Aero. After a bit of trial and error that involved a clamp and running round to the driver’s seat… and back again to adjust I got what I thought was the right height for me.

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As you can see in the photo above, the reflective face of both mirrors is in near perfect alignment… and for me that makes it easy when driving as I don’t have any perceived shift in focus. The picture below is from the drivers position… I put the camera as close as I could to where my eyes are and I get a great view rearwards. Note that installing the mounting clamps on the bottom edge of the door mirror does not block the forward side view over the door mirror.

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The driver’s side was bent the same… just opposite ‘handed’ and the length worked out right for the height too.

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When seen from the front… even though I’m not quite ‘square on’ to the caravan, I’m angled slightly to the left when sat in the drivers seat, the mirror is fully outside the extended side line of the caravan giving me a great view.

To finish…

I gave the now bent and drilled tubes a light emery and de-grease followed by  couple of coats of grey acid etch primer. This was topped off a few days later with a fine bed liner spray.  This game the arms a durable coating plus the bed liner finish is quite ‘grippy’ and allowed the clamps the hold fast without too much yanking on the knobs.

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We have been using these now for about two years and for me they work out just fine.

Shopping…

I had all this stuff in the Bat Cave as it was purchased for other projects, so the mirror arms didn’t really cost me anything. Both arms were made out of one 1 metre length of 12mm steel tube.

The tube bender I paid less than £30 for it about 12 months ago from Amazon. The 12mm Steel tube, again from Amazon was around £4 for a 1 metre length and the Truck Bed Liner paint was around £8.

You can find links to these and other bits I use in the Caravan Chronicles Shop

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Just for comparison…. the original supplied arm against my contrivance…. and yes… I have now sorted that bit of surface rust out! (I missed a bit when spraying)

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TPMS Revisited…

01 Saturday Sep 2018

Posted by in Accessories, Amarok, tow vehicle, Towing, TPMS, VW Amarok

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Its been quite a while since I did my first review of a TPMS (Tyre Pressure Monitoring System) back in September 2015 in fact, on a Tyre Pal system sent to me for review. I did like it but it did give me a few things to think about. Later on I got to test out the Fit2Go TPMS and I ran with that for about 12 months. However I still wasn’t convinced this was the one for me.

With the Tyre Pal I did like the information, but on a screen that size I would have liked to be able to see all the pressures and temps altogether rather than scrolling through each wheel. Although it did cross my mind at the time “do I really need all this info” and that’s why I liked the Fit2Go unit. It sat there quietly monitoring the wheels and just occasionally flashed at me to say everything was OK…. or beeped if there was something wrong. I did eventually miss not being able to see the pressure and temp of each wheel and started to think my earlier statement was flawed.

I had an issue with the Fit2Go unit at around nine months of using it. The batteries in one of the wheel sensors failed… and a couple of weeks later a second battery went down. This was a bit of an issue as the sensors on this unit were sealed and the batteries weren’t replaceable (a plus point for the TyrePal here!) Credit to guys at Fit2Go… now re-branded as Michelin – they sent me out a complete new unit and four sensors. I installed the replacement unit and sensors and ran with that for a while.

Going into work at around 04:45 in the morning, I pulled off our drive the unit started beeping, indicating a low pressure tyre. I pulled over and checked the small LED on each sensor… no flashing red indication.  Tyres looked good, checked the pressure with the  Fit2Go hand-held unit and all as they should be. I  carried on. The beeping stopped. A few days later as I had just got onto the motorway it went off again, pulled onto the hard shoulder, checked each sensor and wheel… no flashing LED and all wheels looked OK. I also took the time to check the pressures again, all OK. On the fourth or fifth time this happened I gave up checking. It only seemed to happen with an early morning start and I started to doubt the info I was getting from the unit.

I started looking around for alternatives… mainly in the US for RV TPMS systems as they seemed to have a greater number of options. It wasn’t long after this that I got the e-Trailer unit to test. Which as well as checking the leisure battery voltage, monitoring the fridge temp and a host of other things had TPMS monitoring for your caravan wheels and sent alerts directly to your phone. With this fitted I had at least covered off the important wheels when towing. I just needed something for the truck. Looking around at  what was available on Amazon.Com in the USA made me realise how much we are actually paying in the UK for this stuff. There were units branded for the American market that were identical to those in the UK for a lot less even with the poor exchange rate.

This set me thinking… could a cheap TPMS available in the UK be as good… were we paying too much? I found a unit on Amazon.co.uk for £50 and ordered one. https://amzn.to/2wv49TS

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The unit had a couple of options for mounting. The sensors had replaceable batteries and were pre-coded to the unit. Each was marked with the correct location… FL, FR, RL and RR.

After much procrastination about where to put the display (it’s a man thing) I could not make my mind up so for the time being it sits on top of the steering column….

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In the few weeks since I installed it.. which was really easy,  it’s worked well. I can set the upper and lower limits for pressure and temp for each wheel and it is fairly accurate on pressure. To test it I used my digital tyre gauge fitted to my compressor in the work shop and checked with a standalone digital check gauge I used to use for aircraft tyres. It always matched the same PSI as both my digital gauges showed and as it didn’t decimal point readings on the PSI setting (you can change it to BAR, as well as from C to F for temp) it seemed to round-up from about .6 which seems acceptable to me. (32.4 PSI would be displayed as 32 and 32.6PSI  would be shown as 33)

It comes complete with a small spanner for the lock nuts, a do-hicky for replacing the battery in the sensors and for £50 it seems like reasonable quality. It does what it states on the box, it’s small enough to put almost anywhere (and that’s my problem… where!) and if you have amazing eyesight… it even has a vehicle battery voltage display right in the centre! And if that didn’t clinch the deal… it even alarms when the batteries are low in the sensors.

So was my £50 well spent? Well at the moment I think so. (I reserve the right to change my mind in the future) You know me by now and if I thought it was a jockey wheel with out a handle…. I’d tell you!

So if you don’t yet have TPMS and don’t want to spend a fortune on one this might be a suitable option.  If you want one… go on you know you do, here’s my affiliate* link on Amazon UK – https://amzn.to/2PX6a3a

*It won’t cost you any more but you will get that warm fuzzy feeling knowing Amazon are going to give Caravan Chronicles some of their profit.

Catch Me If You Can… Part 2

28 Thursday Jun 2018

Posted by in Accessories, Amarok, General, Help Guides, Maintenance, Modifications, Technical, Uncategorized, VW Amarok

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You might want to read Catch Me If You Can… (pt 1) first

After a quick four-day break at the Caravan & Motorhome Club’s site at Wirral Country Park (excellent by the way… already trying to work out when we can go back!!) and a bit of work getting in the way it was time to get going again not he catch can… really it should be called the “Air Oil Separator” Install.

Last time, I’d decided if IKB would have been shaking his head… then it wasn’t right. I decided to make a new bracket out of 1.8mm aluminium sheet and go into full on origami mode. (ps.. after the last post someone emailed me asking what IKB was…. Mr Brunel  was not pleased).

I wanted to make a bracket that passed under the air con pipe and bonnet cable release fitting so that it cleared everything and gave good access at the same time. As a test I did a trial bend if some 1mm thick steel I had just to get the shape…

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Once I’d got the angles and size sorted it was time to move on to the aluminium sheet. My press brake… well I call it a press brake, in reality its a cheap basic hand folding machine but it works very well as long as you know its limits and don’t get daft trying to fold big stuff. It was all about the angles…

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The first two were easy and I could form the lip with two folds, the second was less than 90 degrees so I just about got away with enough clearance. However folding the return that would lip over the front cross brace which was also less than 90 degrees also meant that I’d have a problem fitting it in the folder.

IMG_1453However, a little lateral thinking and taking the blade off the folding machine, inserting my workpiece and re-installing the blade meant I could fold in the opposite direction (downward)… result!

IMG_1454A quick trim and rounding off the edges gave me a rough folded bracket. A quick file of the edges and work-over with some fine emery removed all the tool marks… quickly followed up with a coat of etch prime to protect it.

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I now had to work out how to mount the plastic housing the bonnet release cables were located in. On the rear of the fitting were two plastic tabs that locked into two square holes punched into the vehicles cross member.

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So a few minutes spent with a dremmel and a couple of suitable sized swiss files later…

IMG_1457… and the piece was ready for a final rub over with scotch bright a second coat of etch primer and two coats of black.

The Installation…

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All went a bit easy actually… which is flipping’ unusual for me. I released the bonnet (or ‘hood’ for my American friends) cable fitting and simply clipped it back in to the two new holes I’d made.

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The Provent was installed next…

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… again without any issues. Next was to sort out the plumbing.

I’d done a bit of research and asking around and the guys at ASH… AutoSiliconHose.com had come highly recommended. So a road trip over the Pennines to Mirfield (just east of Brighouse in West Yorkshire) was scheduled.

I had a basic list of what I thought I’d need and the chap behind the counter hooked me up with everything… including the alloy couplers he cut to size while I waited. Great service from ASH and I can definitely recommend them.

Back home with my shopping, it was time to start on the plumbing.

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For securing pipes, I personally prefer spring clips… the type you install with special pillars, however the silicon hose OD was slightly too large for may normal stock of clamps so I had to opt for using the wire type. I’ll order some of the correct size and replace the wire clamps as soon as they arrive.

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It was really simple now to just assemble the bits, cutting the silicon pipe to length as required. I used a pair of plastic conduit cutters to easily slice through the pipe.

Before I made the final connections to the crank case breather port or the turbo inlet port I blew the pipes clear using a high pressure air line.

All that was left to do was install the drain hose, one way valve and drain tap. I used normal 20mm oil line for the drain, inserting the one way valve about three inches below the outlet of the Provent catch can. The remainder of the hose was dropped down to chassis level and the drain tap added and secured with a couple of zip ties.

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The Finale…

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I secured the pipes in a couple of places with zip ties, now I know the route I can make a small stand-off bracket with two rubber lines “P” clips to mount on the engine to hold the pipes, although they are self-supporting because of the short length.

In the photographs above it looks like the piping is tight across the engine, I did do a pull and push test and there is plenty of movement at the 90 degree bends to allow the torque twist of the engine without pulling or pushing on the pipes at the catch can end.

The current mileage is 11,750 or there abouts, so I’ll check the drain and filter in 100 miles and each 100 miles after that so I can get an idea of how the setup is going. I’m not sure how long the filter is designed to last, but Ill put it on the schedule to replace ever main service. The other thing that is an unknown is how much oil I’ll get. I have been watching some YouTube videos made by Berrima Diesel in Australia (if you watch any of the Australian 4 x 4 or off-road channels you will recognise the name). I only found out about their catch can experience when one of the guys from one of the 4 x 4 adventure channels got in touch… even if you don’t think you need a catch can but drive a big diesel their videos are well worth watching.

Ok… I was saying I don’t know how much oil to expect… but it did surprise me that Berrima Diesels posted a video showing a new 4 x 4 with about 6000Km on the clock had produced about 300ml’s of oil using the same Provent catch can. It’s also worth taking look at what the have to say about the current oil specified in diesel engines.

The other thing I noticed was when I left the engine ticking over for about ten minutes. Bearing in mind I had just come back from West Yorkshire via the M62 and M60 and started the pipe install as soon as I got back so the engine was still hot, the difference in temperature between the short length of pipe exiting the crankcase vent and the inlet pipe of the turbo. The pipe exiting the crankcase vent port was almost at the temperature I could not keep my fingers on it, while the inlet pipe I’d connected too was still cool. I’ll have to get my thermomiterbob laser do-hicky out and get some readings… but anything that helps cool gasses going into the turbo has to be of benefit right?

That’s it for now, I know it’s not caravanning related that much… unless you want to get the best out of your diesel while towing. I promise the next one will be caravan related, honest!

As in part one I’d also like to give a shout out to Charles at HumbleMechanic.com for all the information and videos he produces about VW vehicles. Charles has been an absolute gold mine of information for all things VW and if you drive any of VW’s vehicles please be sure to drop in on his YouTube channel and take a look. 

Is A Euro 6 Engine Killing Your Leisure Battery?…

21 Friday Jul 2017

Posted by in Accessories, Amarok, Caravan Electrical Fault Finding, Caravan Electrics, Electrical, Maintenance, Modifications, Off Grid, Technical, tow vehicle, VW Amarok

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OK… so that title was a bit dramatic! However here’s the thing… I don’t think everything is peachy with Euro 6 engines and charging leisure batteries.

If you are a regular reader, you know I have recently installed one of Sterling Power’s Wildside units (and so far I’m super happy with it!) but I did get an email from someone who had read all my postings about it and asked me if it might cure his problem. Here’s the gist of his email….

Note: I have edited this down a bit…. and withheld the name of the person and vehicle.

“I have recently changed my car to a new 2017 xxxxxxxxxxxx and after several trips with it, on arriving home there is never enough charge in the motor mover to manoeuvre our caravan up our drive (which is on an incline) and park the caravan round the back of the garage. I have to plug the caravan in overnight before I can use the mover.

This only seems to have started happening since we changed to the xxxxxxxxxx. I had the caravan’s battery tested at two garages and they said it is OK and it is only 2 years old. The local caravan service man said he could not find anything wrong with the motor mover.

As we are on mains at the caravan sites we visit for a few days the caravan battery should be fully charged.

Can you help?”

This did have me stumped for a bit. Battery tested OK, no issues with the mover, so what was going on?

While doing some of the prep work for writing about my installation of the Wildside unit, I had spent a few days prodding about our VW Amarok with a multimeter and making a few notes about voltages etc. One thing that I did cotton on to was the cyclic way the vehicles ECU seemed to turn off the alternator…. well I should really say put the alternator into “idle” mode. Now with the caravan attached (pre Wildside unit install) I did notice that  at the start it seemed to take longer for the vehicle’s alternator to go into idle mode but also it seemed to stay in idle for a lot longer and I was in the process of trying to work out why as initially I’d have thought it would have been less as it was running the fridge and charging the leisure battery.

A picture is worth… you know the rest. Here’s one of my excellent drawings!

Euro 6 Problem 01

Right, here we go… The drawing shows a caravan plugged into a tow vehicle that has the engine-turned off. Pin 9 is live as it should be, and the habitation relay in the caravan is effectively off allowing the caravan’s leisure battery to connect and power the caravan’s internal 12 volt systems. As the vehicle engine is off, there is no power on Pin 10 the fridge circuit, as this is controlled by the vehicle’s ECU.

Really this could be any vehicle with any engine. Now let’s have a look at what happens with the engine running…

Euro 6 Problem 02

Pin 10 is live, turned on by the vehicles ECU and this powers the caravans fridge. It also operates the caravan’s habitation relay which now disconnects the leisure battery from the caravan’s 12 volt systems and connects it to Pin 9 so that the vehicle can start to charge it.

Again, this could be any vehicle with any engine. This is how our Land Rover Freelander works with our caravan. All straight forward.

Now lets look at what happens when the Euro 6 engine puts the alternator into “idle” (or Eco mode etc.)

Euro 6 Problem 03

This is where it starts to get interesting. I have taken a few liberties here and made a few assumptions. I have shown the vehicle’s alternator disconnected. In practice the ECU doesn’t disconnect the alternator, it will reduce the field voltage and hence the output, not really disconnecting it but reducing the output to a negligible amount.

The ECU will also monitor the vehicle’s battery voltage and continue to allow the vehicles general electrical system to drain the battery to somewhere around 75% charge (this may be a bit of an arbitrary figure) The ECU will then turn on (or up) the alternators output to recharge the vehicle’s battery to about 80%. Why 80% well it needs the remaining 20% ‘free capacity’ so that when you brake, the excess energy of engine braking (regen) can be dissipated into the vehicle battery. Remember that on a Euro 6 engine the alternator is capable of generating round about 2Kw.

Now at this point it dawned on me that something could be happening here, but the idea was a bit ridiculous…. guys with far more agile grey cells than mine must have worked this out and I dismissed the idea. I must have missed a trick somewhere.

I did a bit more checking. I was using two 17Ah sealed lead acid batteries as my “leisure” battery simply because it was quicker to charge or discharge them than a 120Ah battery. For a fridge load I was using 3 x 50 watt light bulbs and it was all jury rigged to a 13 pin plug so I could just plug it in to either the Freelander or the Amarok to make comparisons. I was using a trusty old AVO 8 meter, a couple of digital multimeters and a clamp meter to measure current so really the whole set up was super sketchy for anything that I could write about. I thought that I must have been missing something somewhere and I actually kind of put it to the back of my mind. I just got on with installing the Wildside unit and writing it up.

“DING” You have mail……

I received an email from Charles Sterling with some very interesting information. During testing he had come across exactly the same issue I was pondering over but had put off further testing. I guess by now you have worked it out. Quite simply you can get current flow in the opposite direction… from caravan leisure battery to vehicle battery. In testing Charles had measured a current of around 6 Amps.

It dawned on me that maybe during my initial testing with my jury rigged set up I hadn’t missed something and the readings I had seen were correct. Both Charles and I quite separately had (in my case ‘stumbled’) on a potential issue with Euro 6 engines and caravans.

Back to the original email earlier. It now made sense. The sender of the email was setting off from their campsite to travel home with a fully charged battery (being on EHU while they were on site) and during the course of the drive home, the vehicles ECU was actually reducing the fully charged leisure battery down to 80% charge as it actually thought that the ‘vehicle’ battery was at 100% charge. Hence when he arrived home, the caravan’s leisure battery didn’t have enough charge to run the motor mover long enough to put the caravan away.

So what does this mean in practice?

Well effectively (give or take a bit of loss due to cabling) the caravan’s leisure battery will only get charged to about 80%. You can now think of the vehicle battery and caravan leisure battery as being one battery bank because that is how the vehicle sees it. If the leisure battery is fully charged its voltage will be higher than the vehicle battery so the vehicle will turn off (or down) the alternator so that the vehicles electrical system can drain it to about 75% ready for accepting the excess energy from regen braking. The caravan’s fridge helps the vehicle by draining the battery bank that bit quicker.

This also answers another question. While I was testing, sometimes I’d plug-in my jury rigged setup and if my two little 17Ah batteries were fully charged I’d get a low current drain indicated on my clamp meter. I’d dismissed this to a certain extent, but now I realise that as my two 17Ah batteries were fully charged and the vehicle battery would be at about 80% charge, there would be enough of a voltage difference for a short while, that the two 17Ah batteries would try to equalise with the vehicle battery by recharging it slightly..

Whats the answer?

Well thankfully I solved my problem when I installed the Wildside unit a few weeks ago.

Finally…

If you have had any electrical issues with a Euro 6 engine and towing please drop a comment below. I’ll try to help.

As an aside, I am trying to arrange attending a tow bar installers electrical course with a couple of the OEM electrical equipment manufacturers and one of the approved bodies so I can hopefully increase my knowledge base and widen the number of vehicles I can cover. It’s a bit up-in-the-air at the moment as it would appear its going to cost a small fortune! (Sponsorship deals gratefully received!)

Getting All Charged Up – Update

02 Sunday Jul 2017

Posted by in Accessories, Caravan Electrics, Electrical, Off Grid, Product Review, Projects, Reviews, Technical, Towing, VW Amarok

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The best laid plans….

We had originally intended to spend a week down at Glastonbury which would have meant the 5 hour drive down would have been an excellent test for the Sterling Power Wildside unit’s first outing. However we had to cancel the trip literally the day before we were due to set off. In the few days between installing the Wildside unit and our planned trip to Glastonbury I had been exchanging emails and phone calls with Charles Sterling talking about some of the aspects of the Wildside unit and the direction that caravan electrics was heading in.

Continue reading →

A Step In The Right Direction…

03 Saturday Jun 2017

Posted by in Accessories, Amarok, General, Modifications, tow vehicle, VW Amarok

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OK, so if you read about the bike rack install I guess you might have seen the video of me getting onto the tailgate of the VW Amarok…. akin to a whale wearing a tutu and trying to get on points. I needed something better… well my knees were telling me I better do something about it at least. In the USA, the land of the pickup or Australia the home of the Ute there were plenty of options. The downside was the Amarok has not been released in the USA and shipping charges from Australia are insane. I had to find something closer to home. Doing the usual google searches always ended up with products on sale in different continents so I ended up searching for images that contained the word ‘tailgate’, ‘step’ and ‘Amarok’ and after clicking on various pictures discovered Pegasus 4 x 4 in Bristol. (Note to all the companies out there… spending time correctly tagging and key wording all the photos on your websites pays off!) Continue reading →

Getting All Charged Up – Part 1…

25 Tuesday Apr 2017

Posted by in Boondocking, Caravan Electrics, Caravan Servicing, Electrical, Gadgets, General, Maintenance, Modifications, Off Grid, Product Review, Reviews, Technical, tow vehicle, Uncategorized, VW Amarok

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If you are a regular reader you may remember a couple of posts I wrote about leisure battery charging in caravans and motorhomes (Smart Alternators: how they affect Caravans and Motorhomes…. and NEC Show Roundup – it’s all technical…) and I linked to a few videos that Charles Sterling from Sterling Power has produced covering charging topics and Euro6 engines. At the recent NEC show Sterling Power were featuring a new product that would soon be available that would solve all the issues for caravan owners that were experiancing towing with vehicles that had “smart alternators” which were are standard on Euro5 and Euro6 engines and the issues around regenerative braking on Euro6 engines. Charles promised to send me one of the first pre-production “Wildside” Battery to Battery chargers specifically designed for caravans.

IMG_1127A couple of days ago I was excited to receive   a package from Sterling Power containing one of the pre-production new “Wildside” units. The unit itself is robustly constructed and weighs in at about the same as a bag of sugar – 1Kg.

It comes with a comprehensive 11 page instruction/installation manual that goes through all the steps that you need to install the units and what all the various lights and connections are on the unit itself. For anyone that is familiar with my electrical drawings, Sterling have based their installation drawings on my format so are easy to understand (in my opinion!).

I’ll state now for the record, Sterling Power have sent me this free of charge to install and evaluate and that is what I’m going to do, but I will be honest and tell you if I think there are any issues with the installation or the unit in the way that it operates.

IMG_1131

Looking at the connections for the unit it all looks straight forward. The circuit board is labelled  exactly as the drawings in the installation manual which is reassuring and the manual goes into the various functions of each connection and the programming of the unit.

Why this unit?

Since we had changed from using our 2006 Land Rover Freelander HSE as our primary tow vehicle to our 2016 VW Amarok Atacama I had noticed that our leisure battery was not getting close to a full charge even after towing for a couple of hours. We don’t have a solar charging system installed and relied on the tow vehicle and EHU when on site to keep our leisure battery topped up. I knew about the limitations of smart alternators and have written about them before and answered lots of emails about problems readers were now experiancing. Up to this point I really didn’t have an answer to most of the problems and I was considering going down the same route as our Australian cousins and installing some hefty cables between the tow vehicle and caravan, connected together with Anderson connectors. Works fine down under and would do here, especially coupled with one of Sterling Power’s B2B units which I had been looking at.

Now this would be ideal for us, but anyone who tows using a company car, a lease vehicle or a vehicle on a LP scheme can’t just go ahead and install stuff willy nilly. Unless it is done right, it has the potential to be a bit of a ticking bomb as well and  if I was going to recommend it as a solution there are very few people with experience to do an installation of this type. I have seen some right botch jobs on heavy-duty cabling by so-called “professionals” when installing simple winches and dual battery systems on 4 x 4 off road vehicles. Using a lump hammer, cold chisel and block of metal is NOT the professional way to crimp battery cables!

I was looking round to see if there were other options and talking to the chaps on the Sterling Power stand at the show told me they had a product in development that might just be the solution…. and here we are!

How does it work?

I’m not going to give you chapter and verse on the internals (some of that would be guessing on my part and some is propriety information anyway) so I’ll simplify it as much as I can.

In current tow vehicles you have two connections that supply power to the caravan – one for the fridge which is only live when the engine runs and one for charging the leisure battery which is usually live all the time.  Now the problem is that as it’s quite a distance from the front of the vehicle where the battery and alternator are to where  the leisure battery and fridge are located in the caravan. The size of the cables providing the connections are key to how efficient it all works.

Nearly all good quality tow bar wiring uses 2.5 mm square (2.5mm²) cable for these circuits and they connect between the tow vehicle and caravan through a 13 pin plug and socket (or 12N & 12S in older vehicles). The problem with all this is down to good electrical ‘laws’. In essence the more current you draw through a length of cable the greater the voltage drop ( I go into a bit of techie detail about it here… Understanding Cable and Cable Sizes ) Some people go to the lengths of re-wiring the circuits in 4mm² or even 6mm² cable, which was OK up to a point… usually the point which is the connection between the vehicle and caravan. With the traditional installation what you end up with is two circuits that the voltage is usually too low to provide a good charging capability for the leisure battery and the fridge circuit that might or might not, depending on voltage drop, have some spare capacity but you can’t use it to charge the leisure battery.

Back to the Wildside unit…

What the Wildside unit does and this is really clever, is it takes over the two power circuits, aggregates them and manages the output. It draws the maximum current available through each of the two circuits and provides an output for the fridge always at the correct voltage to maximise the efficiency of your fridge and protect it from the voltage fluctuations inherent with Euro6 and Regen engines and any spare capacity on this circuit it added to the leisure battery charging circuit, steps up the voltage and provides a separate output via a four stage intelligent battery charger to maximise the charging capability to your leisure battery.

This is a very very simple one paragraph explanation, it does have a few other tricks up its sleeve though.

One feature is the “Remote Mode Select” switch option. This allows you to install a switch that will allow you to turn the unit to “Wildside”, “Boondocking” or “Off Grid” mode and run the fridge as though it was being powered from the vehicle. It is actually being powered from the leisure battery.

Take note though… Most caravans and motorhomes are fitted with absorption fridges which use a heated element that is constantly on to make the fridge work. However some motorhomes ( I don’t know of any caravans) are fitted with the more expensive and vastly more efficient compressor fridges which work exactly like your fridge at home but can’t run on gas. If you are camping off grid for a few days with an absorption fridge, then run it on gas. However if you are worried about your fridge not maintaining temperature on an hours ferry crossing or on a euro tunnel crossing then you can use the switch to keep the fridge running. The period you can power it will depend on the capacity of your battery(s)… I would not advise using it with and absorption fridge on a battery bank with anything less than 110Ah capacity.

If you do use this feature on the Wildside unit, it will protect your battery bank from discharging past the safe point by turning off the fridge when the voltage reduces and reaches a critical point that would damage your battries.

You also have the ability to specifically select the type of leisure battries you have installed – GEL I, GEL II, AGM I, AGM II, Sealed, Open, Calcium, LiFePO4 to get the correct tailored charging and maintenance program for your battery bank.

If you are fortunate to have lithium leisure batteries there are a couple of other connections you will need to check out too.

Installation Considerations…

We know what it does so how do we connect it. Well this is where it could get messy unless we have a plan.

IMG_1132

In essence, what do we need to do? Well we have to cut and divert the incoming pin 9 and pin 10 into the Wildside unit and connect one output to the leisure battery. We also need to disconnect the fridge from the caravan’s original control box and reconnect it to the Wildside unit. As the habitation relay is usually buried inside the original control box we need to be able to control this from the Wildside unit. There is a terminal for this (“CVan Dis Output”) but what do we connect to this to make the habitation relay operate correctly?

The original Pin 10 lead that we cut and diverted into the Wildside unit, the other end of this still goes into the installed control box and this will operate the habitation relay. Remember we disconnected the fridge power lead from the installed control box and reconnected it directly to the FRG+ output on the Wildside unit so all it does now is operate the habitation relay.

So summing up, we have to cut 3 cables and re-terminate 5 ends into the Wildside unit. This of course does not include the neutral connections which will be easy and straight forward.

Other Considerations…

The installation of the Wildside unit must be easily reversible so it can be moved to another caravan at some point in the future.

We must also use the correct size cables to connect to the leisure battery as we will now be charging at higher currents than was possible before, the original cable that was installed in the caravan to connect to the leisure battery may not be of a sufficient rating.

We must document the changes properly so that at some point in the future someone can follow what we have done incase they have to fault find.

We must make sure all the connections and general installation are done to a high standard to ensure the installation is safe.

Finally we must be able to do the install without invalidating any warranty on the original installed control unit (i.e. not opening it up) and retain functionality of all the elements of the caravans electrical system. It’s no use installing the Wildside unit if half the electrical features of you caravan don’t work afterwards!

IMG_1130In Part 2…

In the next part I’ll go through the manufacturers electrical schematics of the caravan and show how to find and trace  which cables we are going to look for when we do the install and how we produce a simple drawing showing the changes.

I’ll also come up with a quick check list for all the additional bits (cable, terminals etc) that we will need for the install.