A Couple of Observations............

[Bookwus]

Hiya All,

So I've had the Bug in the shop for the past few days.  Hey!  I work slowly and it's been cold outside.  Cut me some slack here.  Anyway, I brought it in to get two things accomplished.  I was going to update the heat and defrost system and I needed to install the capacitive discharge system I had assembled.  This led me to some interesting situations and some observations.

1.  VW did not design their defrost sytem to be changed out.  Specifically I'm talking about those paper/foil hoses in the front cowl that connect the heater channels to that three way plastic fitting gizmo.  Oh, those were miserable to change out.  VW put a hole in the bottom of the cowl so you can see the hose/heater channel connection.  But that's about it.  You really can't get at the hose to change it out from that dinky hole, much less install the new one.  Finally would up cutting a new hole (1.5 inches) which allowed me some access.  I'll have to fab a couple a covers (ala the inspection plate on the top of the tunnel) for those holes.

2.  Despite the difficulties encountered, I'd really recommend this update.  I replaced all the defroster hosing, cleaned out all the heater channel passageways (gotta love that shop-vac), renewed the insulation on the heater channel footwell vents, and cleaned out the fresh air box.  I used aluminum hosing to replace the paper/foil stuff VW had originally used.  It had partially collapsed internally due to moisture over the years.  Not only that, I found mold inside the old hosing.  Yuck!  This was especially true of the hoses leading to the windshield corner vents.  The insulation on the flapper tongue of the footwell vent now effectively turns the defrost on or off.  Berfore the insulation I always had "bleed-through".  No more of that.  And now, when defrost is on, I actually have defrost!  It really works.  Very strong (at least strong for VW) heated air flow.  Yay!

3.  While it is difficult to change out spark plugs on a regular VW, it's darn near impossible on an AutoStick.  I had to pull my plugs in order to replace them with new plugs (which I had gapped up to .035 to allow for the hotter spark from the capacitive discharge system) and in order to do it I had to remove the control valve and assorted other parts.  Pain in the neck (as it always is)!  But getting the new spark plug wires on was a real challenge.  These wires (Taylor ThunderVolts) are thicker than stock and have a really neat (but impossible to install) tin fitting at the spark plug end.  Take a look: http://www.cbperformance.com/catalog.asp?ProductID=1487  I finally figured out that the only way these wires could be installed is with the engine out and the manifold off.  If you have any ideas about how to get these things installed with the engine in place, I'd certainly like to hear them.  Sheesh, even getting these wires into the shroud retaining clips required filing the clips so the wires would fit. 
I'm sure that I'll appreciate the benefits of the CD ignition (a couple of test runs have been pretty impressive, but I still have some tweaking to do) but all this monkeying around with non-stock parts makes me appreciate the design and craftsmanship of the original stuff even more.

4.  As long as I had to remove the control valve to access the spark plugs, I decided to clean it up.  I took it apart, being very careful not to change anything (like the adjust screw setting) so I could simply reassemble and install.  While I had it out I swapped in a cleaner mounting bracket and a nicer looking air filter.  Got it all nice and shiny (I'll take a picture of the entire engine compartment later today and post it here) and bolted it back in. 



Whoa Nellie!  It was WAY out of adjust.  Super soft on the shifting action.  It took the clutch about 10 to 15 seconds to engage.  I backed out the adjusting screw 3.5 turns before I got an acceptable action.  And I'll have tweak that a bit today.  Anybody have an idea as to why the CV was so far out of adjust?  What could I have done to affect it that way?  And remember, I took reasonably prudent steps to prevent just this situation.  My only two thoughts were that one of the vacuum hoses was loose (tightened their clamps - no effect), or that the new air filter might be clogged up.  I'll try a new air filter today - we'll see.  But if anybody has any ideas....................

The Bug ought to be back to daily driver status by the end of the day.  That's good because after this latest session of finger smashing I'm now at the point where I'd rather be driving than wrenching.

[volkenstein]

Mike,
       Urghh. Had a look at the wires, they look damn difficult to fit the air caps into the tinware. The manfolds/nuts etc interfere with even the stock ones and then you have to poke 'n' prod them to get past them. Maybe some silicone spray? The old fella who sold me a set of Beru wires said to fit it all up and then put a tie-wrap around each one to hold it's position when you try and rip them off. Those Taylors are big suckers too! 8.2 mm...yow, much larger than stock. Got a set of cylinder covers you could experiment with? I'd hate to think you'd have to have manifolds off/on to remove/fit them.

I'm not looking forward to finding out what condition those hoses are in. Bad enough removing them from the donor bug. I thought you could twist them either left or right and that makes them let go?? Putting them back in would be a whole different pain . What hose did you use (brand/measurements etc)?

Plugs? The less said the better. Brings back all sorts of bad memories . Because no PO had used copperkote or even grease I couldn't even undo them until all tinware/shroud/CV/hoses were off. Then I gave it one last try and I could get some torque on them and they finally came....I wonder if Lee has something in his bag of tricks?

The CV probs. I can think of three things off the top of my head.

1. Anything blocking the brass spigot (Carb to CV vac line) on the CV?
2. When you changed filters..no flow issues and did you use a washer between it and the body? I'm thinking maybe the teensy hole got blocked?
3. Maybe you just did a diaphragm at an inopportune moment? Can you swap a spare CV in? Or got a MityVac handy to check the diaphragm is moving?

It sounds suspiciously like the reducing valve can't actuate to release vacuum. Revving or sitting @idle?


Regards
Sean

PS. Congrats on getting some heat/defrost again! I wonder how many are getting around with all that stuff shot to pieces??

[Bookwus]

Hiya Sean,

As a matter of fact I finished renewing the tinware for a 1600 not too long ago.  I used the upper cylinder cover to do a little experimenting with.  I could get the plug cover seated in the tin by doing a little pushing and twisting at the same time.  Not all that difficult really.  However, attempting the same manuever with the engine in the car, manifold in place, and spark plug installed is just an impossibility.  Just one of the problems (but a big one) is that the tinware hole is not perpendicular to the axis of the installed spark plug.  The hole is actually at an angle.  And then there's the issue of getting any kind of leverage on the plug cover.  And on and on...............  I settled for getting the plug caps flush (and somewhat into) the tinware hole.

When I went to remove the defroster hosing (the larger ones leading down the cowl to the heater channel) they just came apart and (sort of) unwound.  I had to pry the remainder of the hose off the heater channel through the holes I enlarged.  A pain in the neck to be sure, but, unlike seating those spark plug wires, this was, at least, possible.   I used aluminum flex hosing for both the larger hose (47mm diameter) and the two upper hoses (32mm).  The third upper hose is the VW plastic hose leading to the center vent.

I'll check out your suggestions concerning the control valve.  Thanks!  The air filter seemed to be fine when I checked it today.  But it really seems that there's a problem with the "air feed" to the CV.  I've also noticed that I cannot shift into the next higher range as quickly as I'd like.  So, I'm guessing that not only is the clutch slow to engage, it is also slow to disengage.  I see more tinkering in my immediate fiuture! 

[68autobug]

Hi Guys,
Well, I have taken My spark plugs out a few times and have a new set to install..
but its easy with the engine out....
but hopefully it won't be out again for a long time....

I've always used anti seize on My plugs so they come out easily...

I have noticed the heater hose that goes onto the heater channel isn't made to be replaced...
once its pulled off.... that it...lol...
I have thought of using solid pvc tubing and pushing into the hole in the heater channel
but My car still has them all attached...
but I have seen then pulled off on cars My son was wrecking...

apart from the ones behind the dash as I'm still debating whether to replace the VW fusebox
with a new Non VW type or by using circuit breakers of which I have already..

I'm still fiddling about with My beetle with the engine out...

but it hit 38.7C today at Noon, and i called it a day..

Lee

[Bookwus]

Hiya Lee,

........I have noticed the heater hose that goes onto the heater channel isn't made to be replaced...

Well, it sure wasn't designed for ease of replacement.

.......but it hit 38.7C today at Noon, and i called it a day..

Geez, that's 102F.  We only got up to -1C.  A big difference in hemispherical temperatures at this time of the year.  Hey!  And something I've always wondered about...................since we both come from the same Mother Country and we share a lot of the same customs......does it seem strange to the folks in Australia to be celebrating Christmas in the middle of summer?  Just curious in view of the fact that the traditional British Christmas is always associated with snow.

[68autobug]

Yes Mike,
imagine being dressed up as Santa Claus with the Hot red suit etc..
they are lucky these days as they mainly stay in air conditioned shops...
but it would have been a terrible job years ago...

its quite difficult these days to give kids outside toys at christmas
as its usually 35C-42C  and its not good for them to be outdoors in the heat..
and you can't give them warm clothes.....

We still have the traditional Baked Turkey,chicken,Pork etc
and the house would be very hot [from the cooking] before We had air conditioning..

and christmas cards do depict snow etc usually....
so most people realise its snowing in the top half of the world..
plus We see christmas on many US TV shows nowadays, with the ice and snow...
and We do have christmas trees, and many years ago, they would be painted
with pressure pack santa snow..  so the leaves would be white...

Many Australian restaurants have Christmas in July [in Our Winter]
so You can get dressed up and have turkey etc...

cheers

Lee

[Bookwus]

Hiya All,

But it really seems that there's a problem with the "air feed" to the CV.  I've also noticed that I cannot shift into the next higher range as quickly as I'd like.  So, I'm guessing that not only is the clutch slow to engage, it is also slow to disengage.  I see more tinkering in my immediate fiuture! 

And I also should have mentioned that when starting up the car I would experience a difficulty in shifting.  The shift lever would not want to move into the proper range.  Some gear grinding was encountered, especially in Reverse.  The strange thing though, was that shifting was easy after the car had been running for some time. 

Well, I located the problem.  Remember previously I had mentioned that I had to remove the control valve in order to access the spark plugs on the left side?  While doing that I had also loosened, but not removed, the hose clamp securing the control valve hose to vacuum reservoir port.  When I buttoned up after getting my repair & installation work done, I forgot about that clamp!  As a result, the vacuum in my vacuum tank was leaking out.  When I went to start up and make that first shift, I had no vacuum reservoir so I got gear grinding and a refusal to shift.  Once the car had sat and idled for a bit, the vacuum built up enough to allow shifting, again with occassional grinding.  I tightened up that hose clamp and all is well.

I guess this is worth remembering in the future when we get a question about why "my car won't shift"

[68autobug]

Every now and then I go round the hose clamps and always find some loose ones...

Lucky You found that clamp
otherwise You would be pulling Your hair out...lol


Lee

[Bookwus]

Hiya Lee,

Hmmmmm..........I wouldn't be pulling hair for too long.  I don't have that much of it left as it is now, LOL.

[68autobug]

Yes,

My hair pulling days are over too...  lol   

Lee

[volkenstein]

X3

An easy fix, gotta love it! As you say Mike, one to file away. That one and the lass (IIRC?) who found the fuse housing was the dodgy culprit.

Lee,
     Speaking of boiling Christmases and insane traditions (roasts on a 40 degree day ), ever made the family trip to visit the rello's? Nothing like being trapped in a vinyl seat car, no air-con, 400 miles and 40 C weather to make those memories last .


Enjoy
Sean

[68autobug]

Yes Sean,

I used to take My family about 180kms away every Xmas for many years
and We didn't have any air con back then...
and black vinyl seats...  Yikes...
and no air con at the other end either...

and they call them the "good ole days" ?

cheers

Lee