Engine Tin Air Flaps

[retro74]

My wire broke on the engine tin vent flaps on my 2.0L D-Jet.

Need advice on replacing wire (source of this part) and fastest installation (rewiring bellows to flaps).

Looks like an engine drop job?

Thanks
Joe

[norustscott]

where did the cable break...in relation to the engine...Pelican has the part for like 10 bucks or less. accessing the thermostat from beneth is possible. The hardest part will be fishing the cable through the engine tin...My thought was maybe you could use the old cable to pull it up through the tin...?

PS. I think you may have the closest 914 to me in Maryland...Sykesville.

To the post...outside of seeing 914's at PCA events...I have only seen 3 on the road in Maryland in three years!

[retro74]

It broke near the flap rod on top of the engine tin, but the wire fell down into the fan housing area from what I can see.

With summer gone, it would matter a bit on warm-up cycle as temps around here begin to drop. I won't be doing much winter driving and will probably drop the motor this winter to repair my battery tray area and paint the engine compartment.

[jabez]

Having just replaced mine, with engine in, you can do it in a couple of hours. Jack up the car, pull the bottom tin off (below the push rod tubes) and work from underneath. Connect the cable to the thermostat bellows and fish the free end of the new cable through the hole next to the dipstick. Have a helper hold the end of the cable you just fed through the hole while you get it in place on the pulley wheel. Onec done, go to the top of the engine, have your helper turn the flaps closed, and connect the cable to where there is no slack. Replace the bottom tin, let the car down off the jack, wipe your hands, pat yourself on the back for a job well done, and go get the cold refreshment of choice for you and your helper.

[John Rogers]

You can use any type of wire such as a piece of picture frame wire and make sure it is somewhat straight. Then let it slide through the hole from the top and with some luck and a little fishing it will come out the bottom. Take the new cable and attach it to the bollows, and insert it through any guides and use a piece of tape to attach it to the wire from above and slowly pull it up. I did mine this way and the hardest part is fishing the wire down from above but you can do it with some patience. Good luck.

[retro74]

Thanks folks...
I looked at the Pelican Parts wire and it looks like a bicycle cable shifter end on the wire. Anyone ever use a bicycle cable for this?

The idea of "fishing" for the cable from above sounds like a winner too. I will probably use a coat hanger for that process since the stiffness allows for direct movement from above. All suggestions are welcome.

Thanks

Joe

[jmcleod]

coathanger will be too big. a piece of telephone wire with the thermostat cable taped (black tape) to it will do. there should be a small circular grommet that the cable goes thru located between the two piece of engine sheet metal. grommet may or may not be critical but it does plug the hole

[bowlsby]

<>

Just get the real McCoy...PP sells it inexpensively...why rig something?

[retro74]

Here's what I did to get it fixed. Thanks for all of your replies.

I have a header and it is easy to crawl under the car and work on this. My car has @ 250,000 miles on it, so the bellows was well encased in grime. Someone should thank the dude that invented WD40... So I took apart the bolt and wire retaining nut and cleaned it up with WD40 and a brass wire brush.

I have a clear view from the pulley up to the top tin. YES a wire hanger fit to thread it up to the top. For the wire, I used an old style bicycle deraleur cable from my old Campagnolo shifters (basically brand new and pre-stretched). I spent 8 summers as a bicycle mechanic and worked my way through college as a bicycle mechanic. These cable are 100-110% of the VW part and they fit just fine.

Not to be frugal, but the bicycle cable is cheaper, easier to get and at least as good. I didn't pay freight and I didn't need to wait for it either. The folks at Pelican don't make much on these (they probably lose money with overhead), since they are such a small and inexpensive part.

Thanks to all for the ideas.

Joe