Cooling air control installation

[jadney@vwtype3.org (Melissa & Jim)]

>From: Greg Merritt <gregm@engin.umich.edu>

>	I believe that I have collected all of the parts required to
>reinstall the cooling air control system (thermostat, pre-heat flaps, etc.)
>in my 1971 squareback.  This system was trashed by a previous owner...
>clearly one who never imagined that this vehicle would be operated in
>sub-zero F. temperatures!.  Due to lack of decent work space, I'm
>considering installing the system without removing the engine from the car.
>
>	Can anyone say for certain whether this is reasonably possible?  I
>know that at least the upper right engine cylinder tin must come off.
>Doable?  Any suggestions would be much appreciated.

Yes, I have done this several times.  You will need to remove the right 
intake air runner, and the right upper and lower cylinder cover tins.  The 
heat exchangers, heads, and exhaust can stay.  You will most probably need 
to use a torch to loosen up the sheet metal screws, so be VERY careful of 
the fuel lines. If your engine needs more work than just this, then it is 
probably more efficient to just pull it.

Note that the bellcrank support slides on the 2 head studs AFTER the 2 
washers (one per stud.)  Don't forget the return spring and don't confuse it 
with the throttle spring; they are similar, but the throttle spring is wound 
in a smaller diameter helix.

Of course I am assuming that the crossbar with the two flaps is still in 
place in the fan housing.  If they are not then it can be done in the car, 
but you will have to pull the exhaust and the fan and housing so it is 
probably less work to pull the engine.  BTW, I recommend that when you have 
everything open, you take a hacksaw and saw a small kerf in the right end of 
this rod, just enough to look like a screwdriver slot.  Be very careful to 
saw it parallel to the flaps and you will have an flap position indicator.  
It will also allow you to insert a screwdriver and gently verify that the 
rod/flaps are not seized.  It's not that I've ever seen that happen, it's 
just that it allows an easy check and peace of mind.  The factory should 
have done this.

Jim
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       Melissa Kepner                                    Jim Adney
       jadney@vwtype3.org              jadney@vwtype3.org
                             Laura Kepner-Adney
                             Madison, Wisconsin
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