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Fitting Thermostat Flaps Without Dropping Engine
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Ben Middleton
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PostPosted: Tue Oct 18, 2016 5:53 am    Post subject: Fitting Thermostat Flaps Without Dropping Engine Reply with quote

Hi guys,

The engine cooling flaps are currently missing from my engine, but I've managed to buy some replacements. I was wondering, can I fit them without removing the engine? If so, does anybody know the best method?

Thanks,
Ben
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Glenn Premium Member
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PostPosted: Tue Oct 18, 2016 6:17 am    Post subject: Re: Fitting Thermostat Flaps Without Dropping Engine Reply with quote

Type 1 or Type 4?
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Bleyseng
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PostPosted: Tue Oct 18, 2016 6:54 am    Post subject: Re: Fitting Thermostat Flaps Without Dropping Engine Reply with quote

His pics in his gallery are of type4 so yes you can! Remove muffler, heat shield, assorted tin and then the half of the fan housing, Install flaps and put everything back together. Then install the thermostat wire so when cold it shuts the flaps and warm opens them. Pretty easy to do all this in a couple of hours unless everything is grimy dirty then clean clean everything esp. inside the fan housing and the fan itself as oily dirt slows down airflow. Do not take the fan apart.
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Ben Middleton
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PostPosted: Tue Oct 18, 2016 8:25 am    Post subject: Re: Fitting Thermostat Flaps Without Dropping Engine Reply with quote

Ahh OK, that sounds good. Yeah, it is a type 4 engine. I thought of taking the cylinder shrouds off and going in that way. Is that a more difficult procedure?
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aerosurfer
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PostPosted: Tue Oct 18, 2016 8:55 am    Post subject: Re: Fitting Thermostat Flaps Without Dropping Engine Reply with quote

You just have to take off the whole induction system, and all top components. Also realigning the big tin pieces with the firewall and lower forward tins may be a pain in the ass.

I have pulled the shroud assembly before with the motor in place. You can get at it without lowering the exhaust, but it's a tight squeeze. I replaced the 4 studs the shroud bolts to the motor on with bolts so it is much easier to remove, should I ever need to in the future
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Ben Middleton
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PostPosted: Wed Oct 19, 2016 8:13 am    Post subject: Re: Fitting Thermostat Flaps Without Dropping Engine Reply with quote

Thanks for the info guys. I'll probably try taking the front assembly off.

Unfortunately I bought a broken cooling flap that I thought was OK. Does anyone have any photos of what it should look like with the clips on there? Also, I don't know how the back of the flap fits inside the hole. Could anyone explain for me please?

Thanks!


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eche_bus
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PostPosted: Wed Oct 19, 2016 3:59 pm    Post subject: Re: Fitting Thermostat Flaps Without Dropping Engine Reply with quote

Here's a photo of the LH flap with everything intact:
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You may also want to look at my build thread here (scroll down a ways to see the flaps installed):
http://www.thesamba.com/vw/forum/viewtopic.php?p=7877018#7877018
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Ben Middleton
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PostPosted: Thu Oct 20, 2016 7:29 pm    Post subject: Re: Fitting Thermostat Flaps Without Dropping Engine Reply with quote

Thanks for adding that photo. I had a look at your build thread too; very informative! I have now replaced my broken pieces.

Today I tried to fit the thermostat flaps. I couldn't see how I could fit them without removing the top shrouds, so I thought I'd remove those first. I removed the inlet manifolds and all the screws for the shroud on the oil cooler side, and then realised that it is trapped behind the firewall. I'm not sure how to get it out.

I have also discovered what seems like a more serious problem. I lifted the shroud enough to fit my hand where the oil cooler flap should go. I felt for the two prongs inside the casing which the flap should clip on to. I could only feel one prong. Is this is a serious problem? Does anybody know of a good solution?

Thanks again for your help!
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