1.6d out - skoda 1.9 aef in

[matt brighton]

Hi

1982 1.6 CS

Quick progress update - and so far so good -

Skoda lump is out and on an engine stand in the garage and i,m a fettling / cleaning /painting etc prior to installation.

next jobs are cam and aux drive belts / clutch / water pump - and (the bit im most shakey on) wiring in the lucas fuel pump - and spigot bearing install.

Colinthefox's guide has been invaluable and a great hekp (thanks colin) as has all the other advice and replies to my earlier posts - thanks chaps.

Quick question - to remove the original engine from the van - do I need to disconnect gearbox selector rods/driveshafts /gearbox mounts ?

Also - the clutch centering tool - will a universal one do as the vw heritage one says petrol only

The "factory" manual only mentions engine connections and tilting the engine down till it can be removed from the gearbox.

Thanks for any replies

Matt - brighton

[colinthefox]

It's a good idea to disconnect the gearchange linkage to avoid strain on the mechanism if you let the gearbox dangle, but you can leave the driveshafts and front mount done up. Of course it's also essential to support the gearbox securely to stop it dropping.

While you have the engine out, it's also a good idea to replace the gearbox input shaft seal, as you won't be able to get at it later.

I don't normally use a clutch centring tool. With the engine out you can easily just nip up the clutch cover and adjust the plate central by eye, before pulling the cover up tight.

If you remove the coolant filler tank, there's enough room to leave the engine and gearbox at the normal angle and just move the engine back to get it out. Be careful not to let it hang on the gearbox input shaft at all.

[kit]

Remember to highlight the timing marks on the fly wheel while it is out, makes it easier to time up later

[matt brighton]

Quick update...

Wednesday - Bad day ! started 10:00am and first job - drill out the dipstick hole on the oher side of the block. The pilot drill broke in the casting and spent rest of the day re drilling from t'other side to meet the drill and punch it out.

Thursday - good day - parts arrived from Brickwerks , 1.6 came out in under 2 hours and i now have 2 engines in my garage - parts from 1.6 being transferred tonight and over weekend.

Plus big thanks to my mate Ray who has helped me with this -

Still a bit worried about the wiring in of the lucas pump (soelnoids /glow plug resistors / as there seem to be alot of stuff like cold start on the old pump that wont be activated ......... but trying to stay focussed on one task at a time.

Thanks again to Kit and Colin for keeping a weather eye on my progress and the commeants advice is much appreciated

Matt

[colinthefox]

The pilot drill broke in the casting

I did warn you!

Don't worry about the pump. It'll be OK

[matt brighton]

I know....

I also managed to break the plastic joint on the vacuum pump too

Thanks for keeping an eye on my progress Colin - I'm looking forward to a productive afternoon in the garage

Matt - brighton

[kit]

The vacuum pumps are different but the top part is interchangeable so just swap them over.

[colinthefox]

the top part is interchangeable

Ohhhhhhhh no they're not.

[kit]

The 1y and CS are for sure.

[matt brighton]

I think the top plate from the cs will with some slight modification fit the aef vac pump - will x that bridge later this week

Regards

Matt

[matt brighton]

Engine went in saturday (with help of my mate Ray) and all going well.

Oh how we laughed when I forgot to install the tin plate that goes behind the flywheel and only realised after we had assembled the flywheel / clutch etc

Couldnt have done this job without help of my friend ray - his engine stand (essential I would say) - hoist and of course Colins almost "step by step" guide - aided by the excellent vanagon manual posted for all to benefit from by oldie but goodie.

And a big thanks to everyone here who has offered knowledge and advice Thank you !

Hoping to complete hoses/wiring etc later today (weather permitting)

Matt - brighton

[kit]

When do you hope to be running again?

[matt brighton]

Hi Kit

I hope to be turning the key sometime tomorrow.

"Just" the wiring to the fuel pump / alternator and the fuel pipes to do.


Then oil n water and - off we go....

Matt

[kit]

Good luck, and try to get used to the sensation of overtaking things

[matt brighton]

Momentus day yesterday - the aef fired up and runs beautifully !

Trouble is...she wont stop when I turn the ignition off

After checking wires and earth connections to the pump stop solenoid and "fiddling " with connections to the other connections it stopped ok about 6 times - then wouldbt stop again.

It was late in the day so we packed up and will be taking another look today.

I will re-check the solenoids (fuel cut off)

Any suggestions on tracing / testing and fixing this welcome



Thanks

Matt