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On 23 Jul 2002, at 10:46, gregm@vwtype3.org wrote: > The first trouble came with a stuck tin screw at the front > of the engine, near the fuel pressure regulator. I torched > it from below, and it came right out. I was then able to > remove the lower tin below 1&2 and get to the thermostat. I find that it is tough, but easier in the long run, to just pull that piece down a little bit and insert the thermostat from the rear/below. > I pulled out the thermostat, then moved the rod up and > down to check it out. It was too loose and floppy, with no > spring action. That's no good. > Well, o.k., so at least I could get that big piece of tin > off. Oops, another tin screw from the rear of the piece > flipped up and landed down near the distributor on the > case. Fished it out, set it on the cargo floor... and it > bounced right into the #1 intake hole. (No, I'm not making > this up.) If it weren't for bad luck you'd have no luck at all! I'm paranoid about this, so I always stuff a rag or paper towel in those holes any time they get opened up. They're just too inviting. > Meanwhile, the flap linkage. Two problems. First, the > piece that connects to the flaps had no washers and no > circlip, and was totally disconnected. Second, this piece > was adjusted at the other end so that the flaps would > always be totally wide open anyway. At least the spring was there (it was, wasn't it?) so that the flaps were still open. > I had another old fan housing half with flaps and this one > rod. I stole the circlip and washers, and somehow -- > somehow -- was able to work upside-down reaching under the > flap to get the circlip in place on that rod. Yes, that's a very tough job! > Meanwhile, what to do about the two tin screw shafts now > stuck in my head? Just leave them for now. A good machine shop can fix them the next time you need a valve job. The rear end of that cover tin is secured around the fan housing outlet, and the front end by the lower tin. An Easy Out will just make you miserable and leave a piece of hardened steel stuck in there. The only way to remove these is to drill them out, and this is best done in a place where the drilling angle can be controlled and held steady and straight. - Jim Adney jadney@vwtype3.org Madison, WI 53711-3054 USA ------------------------------------------------ To unsubscribe, E-mail to: <type3-off@vwtype3.org> For more help, see http://vwtype3.org/list/