[T3] Bracket bolt

[charles tupper]

Yeah...not sure this is worth the struggle. Yes, some screws for the tin are fused to the engine. Also need to disconnect fresh air duct from the exhaust...way too many overly tight screws, nuts and bolts to make this work.  Reminds me I really don't need the Kickdown Switch. What an absolutely stupid design. I thought the Germans were smart!

Sent from Yahoo Mail on Android 
 
  On Tue, May 26, 2020 at 11:35, Jim Adney<jadney at vwtype3.org> wrote:   Charlie,

Ouch, I can understand how that would have come as a surprise, but I think 
you're now about to get into this engine a bit farther than you'd intended. 
Look at the good side: You don't have to get INSIDE the engine, just under 
the tin.

You can do this with the engine IN the car.

To remove the tin, you'll have to remove the generator, the distributor, the 
left side intake air runners, and the left side injectors, plus the little cover 
plates over the spark plug holes and under the injectors. Once all the screws 
are out, it's possible to work the tin up and out of the car. The hard part will 
be getting all the little 6 mm screws loose. Some of them will be rusted solid, 
unless this is a rust free car. The hard screws to reach will be those at the 
front of the tin, including the ones that attach it to the front tin. You'll need a 
very large screwdriver that completely fills the slots in the screw heads. 

You can usually free these by heating the bolts or the weld nuts with a 
propane torch.  Some of them are best reached from below. For all of these, 
watch where your flame is going, because you don't want to burn thru a fuel 
line and start a fire.

Once you get everything apart, this is a good time to replace the oil cooler 
seals and the foam on top of the oil cooler. I have those parts, as well as 
screws and washers, if you need them. I like to replace the screws that hold 
the spark plug tin with hex heads, to make future removal easier.

Take your time. This is difficult but not impossible.

Sorry to hear of your "surprise."  ;-p

Jim

On 25 May 2020 at 23:13, charles tupper wrote:

> I was installing a "new" automatic kickdown switch and needed to pull the
> mounting bracket that sits on the end of the oil cooler over the #3
> cylinder, held in place by 2 10mm nuts. Some brilliant German engineers
> decided to say 3 phennings by not using a nutplate and instead, just using
> a 10mm (hex) bolt. As soon as you loosen the nut, the bolt falls down into
> the oil cooler mount.  I was able to retrieve the aft-most bolt with a
> magnet ... but I can't access the forward bolt.  It looks like the
> tinwork has to come off ... but that is a bridge too far.  Any ideas?


-- 
*******************************
Jim Adney, jadney at vwtype3.org
Madison, Wisconsin, USA
*******************************

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