Date:         Fri, 24 Aug 2007 20:10:57 -0700
Reply-To:     "Georgios A. Stylianides, PhD" <gstylia@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Georgios A. Stylianides, PhD" <gstylia@YAHOO.COM>
Subject:      Exhaust system
Content-Type: text/plain; charset=iso-8859-1

Hi All,

Exhaust system job in progress!

While I took apart the exhaust system (that baby was
rough! … to say the least), I noticed the following:

1. The cylinder heads had a number imprinted inside
the exhaust outlets (see:
http://www.esu.edu/~gstylia/vw/Cyl3b.htm ). It looked
like the cylinders were numbered. The only difference
is that cylinder 1 was indeed 1, cylinder 3 was indeed
3, but cylinder 2 was also 1 and cylinder 4 was also
3. What’s up with that?

2. Inside the cylinders’ exhaust outlets again, I
noticed some type of a rod (see:
http://www.esu.edu/~gstylia/vw/Cyl3qa.htm ). What
would those be, exposed to such a high frying heat?
One of them looked like it was partially melted. I
could be wrong. I’ll check tomorrow.

3. I noticed that one cylinder had white powder
deposits, where the other three were black. What is
the significance of those deposits?

4. I removed the crossover pipes’ studs from the
cylinder heads. I had to wrestle with one of them, but
the others came off easily. I think I made the mistake
to clean the threads of the female stud receiving
holes on the cylinder heads. I say that because the
new studs went in very easily and when I am ready to
put the lock nuts, they will give. Can I use
threadlocker compound to allow for some resistance?
Input?

It looks like studs work better when it comes to
positioning the crossover pipes. In the process, I
found out that 2 of the lower studs are longer (40mm),
in order to accommodate the attachment of push rods’
protective plates. The rest of them should be 38mm).
The bolts should be 30mm. Somehow, my new crossover
pipes do not fit. I may have to use the old one
(original, by the way… 21 yrs old). Tomorrow will
tell.

geo






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