Cracked water flange - 1.6D NA

[tthayer]

The cold weather froze the water in my engine before I had a chance to flush it out with a proper anti-freeze mix. The end result of this is that my upper water flange cracked. I tried JB Weld but it didn't hold because I didn't clean the mating surfaces properly. I'm going to re-attempt the JB weld after scrubbing it pretty thoroughly, but I'm not confident that it'll hold.

The dealership can get the part, but it is $110! None of the wrecking yards around here have any diesels (or any Mk1's for that matter), so repair or finding the part at a remote wrecking yard seem to be the only reasonable options. Does anyone have any thoughts on this?

Also: I'd be happy to buy the part from a forum member if they have a spare one.

[Turbinepowered]

You can clean it off really well, wirebrush it to expose raw metal at the crack, then braze it.

Does the mk1 (which I guess you have, since you mentioned it?) use a different flange than the later 1.6D engines? I have a couple water necks floating about, I could see if one would fit your car and cut you a sweet deal.

[rs899]

I have the same issue, but on the MKII 1.6 engine.  The PO must have been a gorilla (both flanges cracked, worn intermediate shaft bushing from timing belt, etc).

Europarts direct has both flanges  (cheap)for the later engine (same head).  I am sure they will fit yours, but you will have to buy the later senders to fit in the holes.

Rick

[tthayer]

A local welder is going to take a crack at it, but if he finds no success it looks like VW Diesel Parts has one for $15.

I'm so close to getting this running! Patience is key, I suppose.

[tthayer]

Here's a simple diagram showing the flange:

[Turbinepowered]

Just the one sensor hole, then?

[tthayer]

No sensor holes, just two bolt holes on the right side of the flange (with the arrow).

[Turbinepowered]

No sensor holes, just two bolt holes on the right side of the flange (with the arrow).

I think I have one of those. If you want I can take a look, but it'll be Tuesday before I can do that... we'll be out backpacking Sat-Mon.

[burn_your_money]

It's the same as any 8v gas car. You can even put on one of the newer style ones with the sensors in it. It will bolt up just fine. As far as I remember the hose diameters are the same as well

[tthayer]

I looked at a few cabrios and a gasser rabbit, but they all had an extra flange sticking out. I had eyes only for my flange. The flanges of the world kept themselves hidden from my sight. It looks like VW Diesel Parts has the water neck for me. The flange drought has come to an end.

[Turbinepowered]

I looked at a few cabrios and a gasser rabbit, but they all had an extra flange sticking out. I had eyes only for my flange. The flanges of the world kept themselves hidden from my sight. It looks like VW Diesel Parts has the water neck for me. The flange drought has come to an end.

Okay. Mine would have come off a '79 Rabbit engine.

[tthayer]

I ended up using the 2-sensor water neck from a 1.7l gasser. The outlet comes out the left side of the neck instead of the bottom, so it is a really tight fit around the back of the fuel pump. It won't last, but it'll last long enough for me to order the correct part from Jack in Ohio. It runs and drives (and doesn't leak)!
Now I just have to fix the brake pedal and the brake light switch and the wipers and the windshield sprayers and the seatbelts and the...