1970 Karmann Ghia AS project

Sidco7 · 13 March 2010, 22:23

Bookwus - What browser are you using? That might have something to do with it. (thinking out loud)

Hercdriver - Actually I'm in Canada, just North of Bookwus (see member map)

The pump really looks original and has VW markings on the inside. The car was sold new (1970) in Edmonton, Alberta and so may have had some 'cold weather' extras added on.

I'm looking at the vacuum diagram and it looks like the entire vacuum system is operated from the intake manifold. This pump rides on top of the transmission and has (obviously) an inlet and an outlet. I will have to climb back under the car and see if I can trace the lines. (Still cold outside and so I was kind of putting this off) lol.

Cheers, Sid

Sidco7 · 13 March 2010, 22:40

OK,

Under the rear deck, above the transmission is this huge - what looks to be like a heat exchanger, mounted to the underside of the frame. It has piping (which looks like they were long since ripped off) and hoses and wires etc. Haven't a clue what it's for.

I think I will just rip it all out of there if it isn't necessary for the operation of the AS system.

Cheers, Sid

(Bookwus - there should be three pictures attached

Bookwus · 13 March 2010, 23:26

Hiya Sid,

I had this brainstorm that if I tried using the computer downstairs instead of my laptop I might be able to get access to the pictures. I was thinking that perhaps I had a firewall or virus protection installed on the laptop that was preventing the pictures from coming through. But no dice on the downstairs computer either.

Our ISP is Qwest and I'm using IE7 as a browser on both machines. It's gotta be something common to both machines so I'm guessing the problem lies in one of those areas.

Funny thing is that I can see practically all pictures that have been posted in other threads Sid...........except for your postings on this thread and another other thread (I think Kimbill posted those). Very strange! Especially when others can see your pictures!

Hey........enough of my problems........on with your thread!

Sidco7 · 16 March 2010, 03:08

Finished rebuilding the Servo. Looks a lot better than it did thats for sure.
New rubber diaphram and steel ring.

hercdriver · 16 March 2010, 13:25

Quote from: Sidco7 on 13 March 2010, 22:40
Under the rear deck, above the transmission is this huge - what looks to be like a heat exchanger, mounted to the underside of the frame. It has piping (which looks like they were long since ripped off) and hoses and wires etc. Haven't a clue what it's for.

Hi Sid,

That's new to me and looks like some kind of heater. I went snooping around on TS and couldn't find another. What I did notice, is that it looks much like the Eberspracher BN6 heater used on late type II buses. The BN6 lookss larger but has the same duct configuration. The final clue would be a fuel line to support its combustion.

For a list of autostick diagrams, try........

http://www.oldbeetle.com/pcat/epc.html

look at #25 for vacuum related items

Dave

Bookwus · 16 March 2010, 16:07

Hiya Sid,

Just a heads up here.......................

Did you mark both halves of the servo can in order to reassemble it correctly? If you did not it's likely that the 12 mm vacuum port will be aligned improperly. When the servo is in place the vacuum port wants to be pointing toward the driver (left hand) side of the car. That makes it easy to hook up the incoming vacuum hose from the control valve.

And to add to what Dave mentioned about the possibility of as gas fired heater (since I'm still "blind").................. these little numbers were found much more in Canadian cars than in USA cars and Eberspracher did make a BN-4 also. These heaters usually did have an ID plate on them and there would also be plumbing involved for a gas supply line and hot air venting. If indeed you do have a BN-4, treasure it. These little guys can get spendy and there are folks out there who do nothing but rebuild these devices.

Sidco7 · 16 March 2010, 16:50

Thanks Dave for the diagrams - great site. I will have a closer look at this thing today. Should be nice outside.

And thanks Mike for the 'heads up'. I didn't mark the can halves, but took lots of pictures before I took it apart. I will have to loosen the ring and turn the halves to align properly. Nice catch.

hercdriver · 16 March 2010, 16:53

I think I found a picture of your heater.

If you want I have a copy of the manual that I could email you.

Sidco7 · 16 March 2010, 17:16

Dave thats it! and I would love a manual. I will PM you and give you my email address. Cool.

Further on the engine rebuild. The wife and daughter left on a dance festival leaving me in charge of the house for a whole week, so I thought it would be a great time to heat shrink the new cam gear on the crankshaft. A simple operation, but needing to take over the kitchen to heat the oil would have to be done on the sly.

Note to self: don't forget the spacer! Doh!

What was supposed to be a simple 30 +/- minute operation took most of the evening and I burned the Lasagne while I was scrambling around with pullers and rags and hot oil. Lots of fun. Good thing I was alone in the house but I think the neighbours were wondering what the cussing was about.

Oh well, its on there along with the distributor gear and the SPACER.

Don't forget the spacer.

Cheers, Sid

Sidco7 · 16 March 2010, 17:40

Dave, This also solves the 'mystery box' that was posted at the beginning of my thread. The 'spark plug' wire or ignition wire leads out and under the back seat to the relay box.

Good stuff.

Cheers, Sid

Sidco7 · 16 March 2010, 23:57

Namplate doesn't say Eberspracher, but it definitely is a heater.

Cheers, Sid

hercdriver · 17 March 2010, 02:25

You're right. It's not an eberspracher. It's a Webasto.

Here's a manual in German that you may find helpful.

http://www.thesamba.com/vw/archives/manuals/wabastoheater.php

The picture I posted earlier came out of a service manual for VW heaters. Unfortunately it's incomplete. It's not listed as such, but I believe that maybe the same beast you have. The manual only references Eberspracher, but it looks nothing like a BN2, BN4, or BN6. It also shows it in a type IV vehicle.

Sidco7 · 17 March 2010, 02:43

Yup. I'm yanking that thing out. along with all the extra paraphenalia that goes along with it. This is the Okanagan after all, almost California weather anyway. lol.

Sidco7 · 29 April 2010, 20:30

How tight is tight??

OK - I've got the engine back to the button up stage and I'm torquing the case nuts and the main journal nuts and while I do this, I always check the rotation of the crank. I tighten a couple of nuts to the specified torque rating and then turn the crank a couple of turns. Each progressive nut I torque, the crank gets harder and harder to turn. When I have all nuts torqued up, the crank is nearly siezed where it's very difficult to turn.

I checked the main bearing journal clearance with plastigauge and the clearance was within tolerance (0.003").

So - how tight is too tight when it comes to turning the crank after everything is all torqued up?

Post script:
Ya, never mind above. Me being the dumbass that I am, allowed the rear bearing to slip just a bit and didn't notice. Result - new rear main bearing.
Oh well, "and this too, shall pass"