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Exhaust/Heater Box holes
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Wildthings
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PostPosted: Fri Feb 09, 2018 9:53 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

The entire exhaust can normally be replace easily enough with the engine installed. The problem you are going to run into is the connection to the head may be a rusty mess and you may break studs and other wise not be able to separate the heat exchanger pipes from from the heads, in which case for the purpose of drilling out studs and doing whatever else may be necessary then having the engine out may be better.

I would at least attempt to remove the exhaust with the engine in place and then if for some reason the project doesn't go well, evaluate where you are and consider pulling the engine.
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Goach2
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PostPosted: Fri Feb 09, 2018 11:10 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

That sounds like a plan. Now to find a tutorial on exhaust removal.
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Goach2
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PostPosted: Fri Feb 09, 2018 11:38 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Didn't have to look any further than the manual for this:

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Time for some PB blaster...
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Wildthings
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PostPosted: Fri Feb 09, 2018 11:39 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Goach2 wrote:
That sounds like a plan. Now to find a tutorial on exhaust removal.


Considering the condition of your system, if you have a Sawzal you might just cut your old exhaust into more easily manageable pieces. There just isn't much there worth saving.
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JimmieH Premium Member
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PostPosted: Fri Feb 09, 2018 12:29 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Wildthings is correct. Exhaust work in the Rust-Belt can turn into a major project quicky. If it were mine and the F pipes were still good and well sealed to the heads I might consider sticking with the set up you already have and replace only what's needed. I'd start at the end and work back to what's still usable.
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Goach2
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PostPosted: Fri Feb 09, 2018 1:25 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

'F' pipes and the 'U' pipes are pretty much the only good parts. Everything else is either rusty or missing...
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PostPosted: Mon Feb 12, 2018 1:36 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

So I just wanted to confirm the Right-side heat exchanger that WildThing posted. I've seen references to this one being the correct one:

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The duct placement for the fan is different, can anyone confirm which is correct?
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PostPosted: Mon Feb 12, 2018 3:02 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

That is correct for the RH side. It uses a different riser to the booster fan. Round on lower end oval on upper.
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PostPosted: Mon Feb 12, 2018 8:46 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Got the 'F/' pipes off tonight. What do you do with worn studs like these?

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How do you remove them? Any tips in putting new ones in?
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Danwvw
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PostPosted: Mon Feb 12, 2018 9:37 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

A machine shop should be able to change them all for not too much!
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PostPosted: Mon Feb 12, 2018 11:39 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Goach2 wrote:

Image may have been reduced in size. Click image to view fullscreen.


How do you remove them? Any tips in putting new ones in?


Double nut them off. It's easy.


Link

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Wildthings
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PostPosted: Tue Feb 13, 2018 3:28 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

You may be in the "soak for days" situation, as I doubt they are going to come easily. If you find you need to drill them out, cut the flanges off your old pipes and use them for a drilling guide to get your new holes as straight as possible.
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PostPosted: Tue Feb 13, 2018 6:26 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Ok, going to do some 'double-nutting', sounds like fun Smile The passenger side was missing one nut and the driver's side was missing the whole stud. Two studs came out already with the nuts, so hopefully I won't have to do any drilling. As far as the new ones go, should I be applying some anti-seize to them? Should these be double-nutted again to get them in? FYI, motor is still in the bus.
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PostPosted: Tue Feb 13, 2018 9:19 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Also - here's a set of exchangers someone has for sale:

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My question is, is that an EGR port on the left side? And will that work with my 2.0L EGR setup?
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PostPosted: Tue Feb 13, 2018 9:49 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Goach2 wrote:
Also - here's a set of exchangers someone has for sale:

Image may have been reduced in size. Click image to view fullscreen.


My question is, is that an EGR port on the left side? And will that work with my 2.0L EGR setup?


Looks like those have had a bit of repair over the years and could use some more. Crying or Very sad Pictures from different angles would be helpful.
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PostPosted: Tue Feb 13, 2018 11:08 am    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

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Wildthings
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PostPosted: Tue Feb 13, 2018 12:36 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

From what I can tell from the photos, it looks like the left side heat exchanter (the right one in the pictures) has had the cover brazed up where the pipes go through. No problems with that, but check the other exchanger carefully in the same areas to see that they aren't in need of work.
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PostPosted: Tue Feb 13, 2018 12:38 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Thanks, these are local so I will be able to check them out before I buy. What about that EGR pipe? Is that stock and will it work for my setup?
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orwell84
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PostPosted: Tue Feb 13, 2018 12:58 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Here is a good thread on a detailed heater box repair.

https://www.thesamba.com/vw/forum/viewtopic.php?t=613236&highlight=heater+box
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PostPosted: Tue Feb 13, 2018 1:50 pm    Post subject: Re: Exhaust/Heater Box holes Reply with quote

Goach2 wrote:
Thanks, these are local so I will be able to check them out before I buy. What about that EGR pipe? Is that stock and will it work for my setup?


Easy enough to cut it off and have the hole welded up if you don't need it. Have no idea on your smog requirements. Crying or Very sad
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