The bolt length is one M8 X 60 and one M8 X 50. The problem here is
twofold. Allen Sockets should not be used where they are subjected to
road crap and heat. The quality of that VW Kamax hardware is the pits. I
replace these bolts with 316 SS, Hex heads. There is enough room for a
socket. To get them out, I often resort to using the mig welder and
welding another bolt to the hex head. Of course this destroys the
housing but the heat usually helps to loosen the bolt in the head and
this can be done with the exhaust in place.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Chris Hawkins
Sent: Wednesday, September 17, 2003 7:59 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Thermostat housing bolts, 91 westy

Many thanks for all the assistance...and here we go with another PITA.
Just completed a coolant flush and partial hose replacement.  The
plastic
thermostat housing is junk.  All four cover bolts are rust and the
bottom
fitting spins; the cover can not be removed.  Next the bleed valve is
stuck
shut.  So I buy a new unit from Ken W.  Low and behold the two Allan
bolt
heads do not take the 6mm wrench, even when the recess is cleaned before
hand.
What suggestions do you folks have?
One idea is to remove the front exhaust pipes, disconnect the 278 hoses,
carefully cut away the existing thermo house so vice grips can get on
the
bolt head.  A good overnight soaking in PB blaster is in order to.
Does anyone know the dia/length of the two Allen bolts required
A search of the archives indicates many despise this poor bit of
engineering, although my situation is not addressed.
Thanks for reading this and responding.

Chris Hawkins
Lost Nation, NH
91 Westy "Arkle"