> At this point, I don't know if it's the short piece of hose, it's
> connection to the flange to the head, the flange itself or the
> connection to the head that's the problem, but it's right in that one
> and a half inches somewhere.
>
> What's that flange made of, plastic or metal? I had it in my hands when
> I did the head gaskets last christmas, but I can't remember.

Well, as I understand it the factory original elbow piece is plastic and is
notorious for going to pieces. My own '90 had a crazy-ass backwoods
"replacement part" that looked like it was an exhaust flange sawed off a
lawn mower. I have since replaced it with the real VW replacement which is
now made of metal (025 121 171). They were on perpetual backorder for 6
months or so, but now it seems all the vendors have a few.

What's the best way to get to it?

The best way? Drop the back end of the engine/transmission and remove the
muffler, carrier bar, and mounting harware! OK, so that's probably not
actually easier than the "normal" way: get the alternator (and maybe the PS
pump) out of the way and fumble at it from above. Probably the hardest part
is dealing with the hose clamps on that short bit of hose. I replaced the
evil cheese-grater clamps on a piece of old heater hose on mine with the
spring-type clamps (N 016 404 1) and a real replacement hose (N 901 287 03
). Also, a gasket for that elbow flange (N 901 288 02 ).