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Fri Oct 01, 2004 8:56 am

Well drove the bus to work. Drives just fine, but I almost passed out when I got here and I'm still sick to my stomach. Where do I need to seal/ patch up place where the exhaust is getting in?

I have a 77 asi so I got the access panel under the bed, that will be the first place. do I need to buy the seal or can I just buy something at Home Depot?
Also there is a hole where the spare tire could fit, plug that too?

For Heat, one of the tubes on the right is a standard acordian style but it connects to a oblong hard plastic piece, Square hole and round peg no workie! :?

Is there any other areas?

where can I get exhaust studs?

Fri Oct 01, 2004 9:08 am

nwavant wrote: I have a 77 asi so I got the access panel under the bed, that will be the first place. do I need to buy the seal or can I just buy something at Home Depot?
What panel?

Quote: Also there is a hole where the spare tire could fit, plug that too?
That's a drainage hole and has a small plug in it.

Quote: For Heat, one of the tubes on the right is a standard acordian style but it connects to a oblong hard plastic piece, Square hole and round peg no workie! :?

Is there any other areas?
I would start with the rear seals on the hatch and the engine lid and then check the flapper boxes.

Quote: where can I get exhaust studs?
VW dealer.

Fri Oct 01, 2004 9:19 am

panel/ access hatch under the bed...If I lift out the bed, then pull up the carpet there is a hatch/panel to access the engine. I think that needs to be replaced.

Also no plug in the tire holder.

anyone know the part number for the studs?

thanks!

Fri Oct 01, 2004 9:24 am

nwavant wrote: anyone know the part number for the studs?

http://www.germansupply.com/xcart/customer/product.php?productid=16279

Fri Oct 01, 2004 9:36 am

Thanks!

Fri Oct 01, 2004 11:03 am

nwavant wrote: panel/ access hatch under the bed...If I lift out the bed, then pull up the carpet there is a hatch/panel to access the engine. I think that needs to be replaced.
Is the seal there missing?

Fri Oct 01, 2004 1:30 pm

If you are getting that much exhaust inside, it has to be coming from the heat exchangers. "hippy fix" disconnect the heater hoses from the flapper boxes. Only real fix is to replace the heat exchangers.

Fri Oct 01, 2004 1:41 pm

no the seal is there its just 27 years old and I'm not sure if its keeping all the C02 out.

But my bro just came by and said that I can close the dampers or close the heaters off fully so that way if there is a leak in the heaterboxes they would not be sucking the c02 into the cab.

yeah what he said...how do you do that?

Fri Oct 01, 2004 10:39 pm

Get under the bus, in front of the rear wheels. Wiggle towards the back, until your just in front of the engine. At each side, you should see the end of the heater boxes, a big black accordian hose, going into a fitting that has a cable attached to it. Those fittings are the flapper boxes, and there is a flap door inside each one controlled by the cable (the other end connects to one of the dash levers). You could close the flap with the lever (move the levers so that they are beside the narror ends of the red triangles), and it should solve your problem for now, but if that doesn't work, you can undo the accordian hose, and put it beside the flapper. The exhaust will then be ejected under the bus. Right now I have one heat flap wired open, and one wired shut, because only one of my boxes has a bad leak.

This is a temporary fix, as your real problem is probably rusty heater boxes, replacements are about $100 new. The exhaust should NOT be coming up from your engine compartment at all! It should be just fresh air, above the engine tin. Your compartment ought to be sealed from the underneath. Is it sealed completely, around the edge of the tin?

Jeremy

Sat Oct 02, 2004 7:00 am

great I'll jump under the bus today and fix that, well close that.

I'll also take some pictures of the tin and the seals so you guys can let me know what need to be fix, found, replaced.

thanks for the help....

now after this issue to get rid of the knocking in the engine :oops:

Sat Oct 02, 2004 10:05 am

their simplicity and engineering, I've never thought the heater boxes and heat system safe whent the get old. And, my 1st VW was a '63 bug with "fresh air" heat. Even when working properly there is too much chance for CO. Incidently, the #1 thing that kills truckers isn't accidents, it's CO.

Anyway, I just pull the accordian tubes between the boxes and the air handlers and shoved spray can plastic lids over the tubes. That way, I can suck up random dirty air from behind. And, I just go without heat as by the time I get to most places around here it wouldn't be warmed up anyway. This year tho, I think I'll get one of those clean burning tent propane heaters.

Happy trails, Mark

Sat Oct 02, 2004 8:21 pm

Ok, climed under the little lady and found that:

a. HEadter box shot to hell, rust ate it.(see pictures in the morning, maybe)
b. Flapper on the other side no workie (pos)
c. JB WELD on most of the exhaust connections (PO DUMB A**)
D. Looks as if I ned to start hunting sme new exhaust systems. Any compleate kits out there that are for the 2.0?
oh and
E. Head gaskets must be gone becase there is oil everywere and a I need to replace the right rear CV boot.

well tons more with teh bus too bus one set at a time.

I did see a flyer at bow-wow for Octobugfest comming up in 2 weeks you think there will be heater boxes there?
and can I change out the head gasket with out removing the engine?

ok now time to drink! 8)

Sat Oct 02, 2004 9:00 pm

Are you sure its head gaskets or is the leaking coming from old push rod tube seals? I don't know about Octobugfest, last year there didn't seem to be much in the way of type4 parts. I guess your close enough it's worth a try. I do know that the club I'm in, WetWesties, has a campout Saturday night before the show at Dash Point campground. Kind of fun to carabus the next day to the show.

Sun Oct 03, 2004 5:37 am

I would totaly love to kick it bus with out it runing wll and safe I'm going to ride with a buddy...

I hope some one has something...