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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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 Posted: Mon Jun 29, 2015 8:09 am Post subject: Generator replace help!!! |
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| The generator in my 1972 VW Super went bad some time last week. I went ahead and bought a new one since everything I read online made the job seem fairly easy. At the bottom of the panel that attaches to the fan, there are two screws that are blocked by dual port intake manifold. I tried to remove this but there are two nuts that I cannot reach with any socket or wrench that I have tried. Do I have to take this to a shop? I'm so frustrated with this. Please let me know |
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APPLEGREENVW
Samba Member
Joined: November 30, 2003
Posts: 2387
Location: Seekonk,Massachusetts USA
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Harleyelf
Samba Member
Joined: April 23, 2009
Posts: 1572
Location: Appleton, WI
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| Posted: Mon Jun 29, 2015 10:10 am Post subject: |
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Loosen the right manifold, remove the left one, loosen the clamps on the rubber boots and slide the boots onto the manifold tube, and remove the nut behind the distributor that holds the manifold tube to the case. Remove the throttle cable from the carburetor throttle lever and unbolt the pre-heater screws from the exhaust.
Now the manifold tube should slide to the left and lift enough to access those pesky fan bolts. No need to disconnect the fuel lines. |
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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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| Posted: Mon Jun 29, 2015 10:15 am Post subject: |
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| I can't access the nuts to pull the manifold off either. I can't get a wrench to fit in |
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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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| Posted: Mon Jun 29, 2015 10:44 am Post subject: |
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| I can only get a very small 1/2" wrench in and I can only push it counter-clockwise. Is this the right direction? if it is then I'm just not pushing hard enough |
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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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| Posted: Mon Jun 29, 2015 11:39 am Post subject: |
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These are some pictures of the nut. The nut is directly behind the red plug. As you can see it is almost impossible to reach. I can't get it to turn at all[/img] |
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Cusser
Samba Member
Joined: October 02, 2006
Posts: 31355
Location: Hot Arizona
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| Posted: Mon Jun 29, 2015 12:18 pm Post subject: Re: Generator replace help!!! |
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| jcoo9614 wrote: |
| The generator in my 1972 VW Super went bad some time last week. I went ahead and bought a new one since everything I read online made the job seem fairly easy. At the bottom of the panel that attaches to the fan, there are two screws that are blocked by dual port intake manifold. I tried to remove this but there are two nuts that I cannot reach with any socket or wrench that I have tried. Do I have to take this to a shop? I'm so frustrated with this. Please let me know |
Here's what I've always done (1970 and 1971 VWs with generators). I disconnect battery negative terminal. I mark the position remove the engine lid. I remove the accelerator cable and pull through the fan shroud and the wires - you mark the wires, you don't have my experience, or you wouldn't be posting this topic). I disconnect the strap holding the generator to the mount/stand. I remove the carb from the intake manifold. I lift the entire fan shroud up and out of the VW, and work on it out of the car. So I leave the intake manifold in place.
By the way, a "1/2 inch wrech" has no place near a VW wnfine, those nuts take a 13mm wrench. Or you could use JIS Japanese nuts which take 12mm wrench.
_________________
1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297 |
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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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| Posted: Mon Jun 29, 2015 1:26 pm Post subject: |
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| how do I take out the fan shroud? |
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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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| Posted: Mon Jun 29, 2015 1:36 pm Post subject: Re: Generator replace help!!! |
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| Cusser wrote: |
| jcoo9614 wrote: |
| The generator in my 1972 VW Super went bad some time last week. I went ahead and bought a new one since everything I read online made the job seem fairly easy. At the bottom of the panel that attaches to the fan, there are two screws that are blocked by dual port intake manifold. I tried to remove this but there are two nuts that I cannot reach with any socket or wrench that I have tried. Do I have to take this to a shop? I'm so frustrated with this. Please let me know |
Here's what I've always done (1970 and 1971 VWs with generators). I disconnect battery negative terminal. I mark the position remove the engine lid. I remove the accelerator cable and pull through the fan shroud and the wires - you mark the wires, you don't have my experience, or you wouldn't be posting this topic). I disconnect the strap holding the generator to the mount/stand. I remove the carb from the intake manifold. I lift the entire fan shroud up and out of the VW, and work on it out of the car. So I leave the intake manifold in place.
By the way, a "1/2 inch wrech" has no place near a VW wnfine, those nuts take a 13mm wrench. Or you could use JIS Japanese nuts which take 12mm wrench. |
How do I take out the fan shroud? do you have a video for this? |
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GArBa
Samba Member
Joined: January 27, 2014
Posts: 2105
Location: Milano, Italy
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| Posted: Mon Jun 29, 2015 2:23 pm Post subject: |
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| jcoo9614 wrote: |
| The nut is directly behind the red plug. |
your pics aren't surely the best, but it looks to me that red plug isn't a plug at all. it's the bakelite/plastic insulator at the end of the HT lead that somehow has stayed attached to your plug (it should come off together with the HT lead). once removed that, the actual spark plug's tip should be barely visible through the cooling tin, ensuring a much better access.
that said, to work around a beetle engine compartment with a socket wrench, you will need, aside from the correct metric bits, a lot of extensions and universal joints.
Or, you can use small low profile metric wrenches, dentists'mirrors and huge loads of patience.
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cars:
'97 type 1 1600i
'14 type AA Seat Mii (sadly dead after 270.000 km)
'22 type C1 T-Cross
'23 type AC3 Hyundai I10 (VW no longer makes small cars!)
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'82 Benelli Magnum 3v |
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iowegian 
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Joined: February 16, 2005
Posts: 9829
Location: Somewhere between Dubuque and Keokuk
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| Posted: Mon Jun 29, 2015 2:29 pm Post subject: |
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| jcoo9614 wrote: |
| how do I take out the fan shroud? |
Remove the engine from the car. |
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Kiptere
Samba Member
Joined: February 13, 2013
Posts: 419
Location: Houston
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| Posted: Mon Jun 29, 2015 2:30 pm Post subject: |
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Just pull the fan shroud and generator off all in one piece. Disconnect the fan shroud. Disconnect the generator strap. Leave the generator plate connected to the fan shroud. Remove the rear deck lid. Remove the deck lid hinges. Pull the whole fan shroud and generator up and out (all in one piece). I replaced my generator a couple of months ago and this is how I did it.
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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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| Posted: Mon Jun 29, 2015 4:36 pm Post subject: |
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Do I have to remove the engine to take off the fan shroud?
P.S. I really appreciate all the help |
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APPLEGREENVW
Samba Member
Joined: November 30, 2003
Posts: 2387
Location: Seekonk,Massachusetts USA
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iowegian
Samba Curmudgeon
Joined: February 16, 2005
Posts: 9829
Location: Somewhere between Dubuque and Keokuk
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| Posted: Mon Jun 29, 2015 5:36 pm Post subject: |
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| jcoo9614 wrote: |
Do I have to remove the engine to take off the fan shroud?
P.S. I really appreciate all the help |
You don't have to, but quite honestly with all of the trouble you seem to be having, it might possibly be easier in the long run. (or not). |
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Q-Dog
Samba Member
Joined: April 05, 2010
Posts: 8699
Location: Sunset, Louisiana
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| Posted: Mon Jun 29, 2015 6:56 pm Post subject: |
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I have changed a few generators and only once did I do it with the engine in the car. NEVER again! So much faster and easier to pull the engine.
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Brian
'69 Dune Buggy
'69 Beetle Convertible
'70 Beetle |
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Zylinderkopf
Samba Member
Joined: September 09, 2012
Posts: 679
Location: SE Oklahoma
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| Posted: Mon Jun 29, 2015 9:25 pm Post subject: |
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Here's a good video on how to replace the generator with the engine in.
http://youtu.be/4ewXkdPgsa4
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1963 Beetle
1966 Beetle 1300
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"A lot of people never use their initiative because no one told them to." |
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iowegian
Samba Curmudgeon
Joined: February 16, 2005
Posts: 9829
Location: Somewhere between Dubuque and Keokuk
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| Posted: Tue Jun 30, 2015 4:53 am Post subject: |
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I love how the expert mechanic uses his ratchet handle as a hammer at 4:46.  |
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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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| Posted: Tue Jun 30, 2015 6:55 am Post subject: |
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| I finally got the manifold off but in the process I dropped a 13mm socket into a pipe that a hose was attached to.... I'm wondering if I have to take that apart to remove it or can it be left in there (Stupid question I know but humor me please) |
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jcoo9614
Samba Member
Joined: June 29, 2015
Posts: 25
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| Posted: Tue Jun 30, 2015 7:30 am Post subject: |
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The socket fell into this
it fell into the little extension on top |
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