TheSamba.com :: View topic - piece of fuel pump flange fell into top of block

Fri Apr 11, 2008 8:06 pm

When I was changing my fuel pump flange a piece of it broke off ( about 1 1/2 inches long) and went into the top of the block. I can't see it when I look into the hole and I'm not sure if it went through to the bottom or if it is laying on the gears somewhere. I was told by a friend to take off the generator stand and try to access it from there and my brother-in-law told me I had to take the engine apart.

Does anyone have any advice on how to get it out without taking the engine apart? Please help!

Oh, I forgot, I have '71 Super Beetle Auto Stick with a dual port 1600CC engine.

Fri Apr 11, 2008 8:22 pm

Oh boy that's the ugly part. You should take off the oil plate where you drain the oil. That could help to get the part that fell down in the engine.

Fri Apr 11, 2008 8:30 pm

Was thinking about that, but not sure where it could've gone. What about taking off the front pulley and removing the oil pump and going in that way?

Fri Apr 11, 2008 8:37 pm

Stephaniempvj69 -

Been there done that. Don't worry too much.

A piece that large should be fairly easy to extract.

There is no way a piece that large can fall all the way to the pan.

It has probably fallen straight down and is just sitting up next to the gears. I would look to the upper left of the fuel pump access hole.

Get yourself a mini LED shop light so you can look down into the block.

You will also need some flexible claws.

Good luck.

Pat (66foot)

Fri Apr 11, 2008 8:46 pm

I will give that a shot, good to know I'm not the only one who's done this.

Fri Apr 11, 2008 9:13 pm

Stephaniempvj69 -

See the enclosed photos for the tools that are useful for extracting "stuff".

The mechanics claws have both straight teeth and hooked teeth. From experience I have found that the straight teeth work best for this job, especially since you do not have very much room to maneuver.

Your FLAPS or Sears should have these tools.

The green tool is a flexible magnet for when really bad things fall into your engine.

Pat (66foot)

Fri Apr 11, 2008 9:19 pm

I have found that the flexible magnetic one works wonders - especially if you cant see it, just swish that thing around in there until it picks up the part (unless of course the part isnt magnetic). Good luck, you shouldnt need to split the block to get something like that out.

Fri Apr 11, 2008 9:20 pm

I found the claw on sears.com (available in store close to me), but not the light. Does it have a specific name other than mini led light? Would wal-mart or auto zone have them?

Fri Apr 11, 2008 9:25 pm

Stephaniempvj69 -

Bend-A-Light

I believe that I purchased it from Sears. It may be a regular incandescent light.

Pat (66foot)

Fri Apr 11, 2008 9:36 pm

Cool, thanks. I'll check on it tomorrow when I go up there.

I'll let you know if I get it out or not, hopefully I will. If I don't I won't be going to the Texas Classic next weekend.

Fri Apr 11, 2008 9:38 pm

I hope that you don't miss the Texas Classic.

When you go to replace your push rod and intermediate flange, I highly recommend CB Performance - they are awesome VW OEM.

See the pictures below:

Don't forget to pack the pump.

Without Grease

With Grease

Pat (66foot)

Fri Apr 11, 2008 9:38 pm

jon68 wrote: I have found that the flexible magnetic one works wonders - especially if you cant see it, just swish that thing around in there until it picks up the part (unless of course the part isnt magnetic). Good luck, you shouldnt need to split the block to get something like that out.

Yeah, the one bad thing about the flange, not metal. Wish it was or I would've already had it out, magnets we have, claws not (don't know what happened to the one we had). Hopefully better news tomorrow.

Fri Apr 11, 2008 9:41 pm

66foot wrote: I hope that you don't miss the Texas Classic.

When you go to replace your push rod and intermediate flange, I highly recommend CB Performance - they are awesome VW OEM.

See the pictures below:

Don't forget to pack the pump.

Without Grease

With Grease

Pat (66foot)

I have the replacement flange already, but did not know about packing the fuel pump with grease. What do you use for this?

I forgot to ask you, what is the easiest access point to retrieve the piece of flange? I don't think it will come out the way it went in, it's in one piece, not broken off or a hunk.

Fri Apr 11, 2008 9:49 pm

Stephaniempvj69 -

I use Mystik Tetrimoly for the packing and I put a light coating of Engine Assemply Lube on the push rod.

Pat (66foot)

Fri Apr 11, 2008 9:54 pm

Pat,

Thanks for the info, noone told me I had to do that.
Will report back tomorrow and let you know how things went.

By the way, I don't know if you saw what I added, what is the easiest way to gain access to the area. I don't think it will come out the same way it went in.

Stephanie

Fri Apr 11, 2008 10:01 pm

Stephaniempvj69 -

Once you locate the piece, then figure your best angle of attack. Probably the Bend-A-Light in the center hole and the mechanics fingers around the outside.

You do not have very much room to maneuver, that is why I suggest using the mechanics fingers with the straight claws. They, will give you about an extra 1/8" of lateral maneuverability.

Be patient and you will be able to remove it.

Pat (66foot)

Sat Apr 12, 2008 9:25 am

Or try going in through the oil pump opening. That is probably where the piece will be.

Sat Apr 12, 2008 3:32 pm

Use a vacum, duct tape a small hose on the end of it put hose down in motor, it might find peace that fell in. Good Luck

Sat Apr 12, 2008 4:54 pm

Thanks for all the help guys, we were able to get the pieces out by using the claw as 66foot suggested. We pulled out 2 pieces about 1 1/4 long, it broke in half when it went through. Did not notice any thing else in there, already changed the oil and only saw a few bits in the screen. Starts and runs fine.

Sat Apr 12, 2008 8:48 pm

Texas Classic all the way...

Good job!

Pat (66foot)