Club 80-90 Forums

Hi All im new here - ive just bought my first van, and within 3 hours of ownership managed to kill the engine (I didnt realise the dipstick wasnt reliable- doh). Anyway so another identical 1.9D 1y is on its way, and im looking for instructions on removal and replacement. I am a novice but have some experience, and keen to use this as a learning opportunity!

Any direction would be appreciated

Thanks!

Directions wise, it's at the back. Hope that helps..

Good luck!

Err and there are guides to fitting a 1y - prob should read those and don't forget the bearing in the crankshaft.

It's really easy taking an engine out, i used a crane, people use jacks, not sure I'd fancy that without help

Removal will be the same as the 1.6 JX.

I reversed the van up onto ramps and placed a wheeled 'dolly' underneath the engine/box. Then used a standard engine hoist to drop the whole lot onto the dolly. A couple of straps and a good heave gets it out from under the van.

It's not easy to describe how to drop an engine and box, other than to say disconnect all the easy stuff (Fuel/throttle/coolant/electrics), douse all the main mounting bolts in WD40 or whatever your favourite flavour is and slacken them off to make sure they will come away. The last thing you want to be left with is an engine hanging in place with 1 bolt. Single-Hex sockets are a must. Suspend everything on the crane and unbolt without crushing yourself.

Make sure you have good quality hexagon keys for the CV bolts as they turn into chocolate very readily. Lift the driveshafts out of the way as they will catch on the cups when lowering the engine and box to the floor.

Best of luck.

Dave.

Thanks Dave that's helpful.

If someone could link me to the refitting info it would be super.

Cheers

Steve

As a side note, you don't need to take the box out when changing the engine. Just make sure it is supported from above so it doesnt hang down when disconnected from the engine...

It can be fiddly to mate the box back up to the engine this way...

Ringo

I must admit that the next time I do an engine swap I will drop the engine and gearbox together. As I work alone it was a pig getting the two to mate easily although the first swap I did they mated as easily as a red light district worker.