That flattening is the way it's made at the factory. It's a really tight fit!

Stuart

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Dan N
Sent: Tuesday, September 22, 2015 7:13 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Coolant Drain - 2.1 L

I wish I have better memory to help...

about 4 years ago, on a trip to Oregon the water pump on my Suncro broke...
Scott replaced the water pump with me as a helper... we worked for 6 hours straight, without removing the pulley or the muffler... I don't remember how we did it...

today I went under the van a have a look.. I notice that the metal cross pipe (under the pulley) was flattened just a bit - nor even .5"..

this could be your solution...

please ask if you need a pic of it...

dan