Hi Guys

Can you guys help me out with how the stuff goes through the doghouse shroud.

Ye Ye, Just push it through.

I mean the Accel cable, is there anything else that is supposed to be with that like a sleeve or grommets, same with the fuel line.

Plus is there anything else that goes through.

Thanks Trev

There should be a tube around the throttle cable - goes through the fan shroud from the carby side, then through the rear (front) tin at the firewall. Then you push the cable up the tube from underneath.

The fuel line SHOULD NOT go through the fan shroud... it has a grommet in the rear tin, and then skirts around the LHS of the fan shroud to the fuel pump. Every standard beetle I've seen this part of the line is metal, and only goes to flex stuff just near the fuel pump.

Nothing else really goes through the fan shroud... wiring etc. all duck around the sides. Make sure everything on the firewall side is nicely secured so there's no chance of being sucked into the fan.... can be a bloody scary sound when that happens...

Make sure you have the thermostat flaps attached at the bottom of the shroud before you install it. They are vital as they control the direction of the cooling air flow over the cylinders and heads - never leave them off.

Ideally you should fit the thermostat too, but you can live without it (it controls the engine warm-up on cold starts).

The oil cooler should have foam around the outside of it so it seals against the shroud once it's pushed down into place. This means all the air in the 'doghouse' extension goes through the cooler, not leak around the outside of it.

Oh No

The engine is in, what are Thermostat flaps. Frikken heck, there is always something hey. I silastic ed up all the spare holes and put a bead around all the metal joins as some where not a good fit.

They look like this - the fan shroud has been removed and turned upside down to show you. There should be a set on each side, joined together by a link. A rod connects the whole shebang to the thermostat.

The idea is that at cold the thermostat pulls the flaps closed so the engine warms up faster. As it warms the thermostat opens the flaps and the engine gets maximum cooling. As you can see, even fully open they change the direction of the air at the bottom of the shround, in a way carefully designed by the VW engineers. Leave them off and the cooling is buggered up.

Read more here - http://www.vw-resource.com/vw-resource.com_non_ssl/vanes_thermostat.html 

I totally agree with all of the above, but on many cars these are lost/not fitted usually because the 'mechanic' knew better, so they are quite hard to find. Also all the knock off non og fan housings don't have the provision for them, but should be able to fit with a bit of work. Even not working they are best in there.
Also when the doghouse fan is used you need to get the extra air in by having the correct 4 vent decklid or permanent standoffs. I don't recommend the prop at the bottom as it sucks id hot air from the engine and exhaust. All this only tends to make the difference on a hot day.......