Date:         Sun, 2 Sep 2001 11:52:34 -0700
Reply-To:     Warren Chapman <tallsound@MY-DEJA.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Warren Chapman <tallsound@MY-DEJA.COM>
Subject:      Re: Syncro starter removal question
Content-Type: text/plain

Rich,

This is one sorry job.  I  did it when doing an engine conversion on my Syncro Westy.

Too bad you cut the rubber sleeve.  Bently doesn't tell you two important things.  First, the two bolts that hold the servo in place only turn on their outboard ends.  The nuts are welded(glued) in place.   Second, and probably most importantly, Bentley  doesn't tell you to remove the vacuum lines first.   Duhhh!  Then the servo pulls away from the rubber easily.

I used a small drift punch to remove the pin.....but careful.....that tiny pin is easily lost.  Also be careful with the plunger shaft.  It is easily bent.

The next fun part is getting the starter out and after I got it out, I couldn't get the new one back in without dropping the engine down  What a PITA!   My  mechanic does it without doing this but I couldn't.   I'll let him do the next one.

There is a very detailed account of the whole job on the Syncro  list at Yahoo Groups and on Syncro.org.   Read it before doing anything else drastic.

Be prepared for lots of swearing (or mantra reptitioin) and skinned knuckles...and as my uncle used to tell me when we were fishing...(the secret is) ....."You have to hold your mouth right".

Good luck,

Warren C.



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