Club 80-90 Forums

Hi All,

I need to remove the 1.6D engine, prior to dropping in the 1Y.

Bentleys photos show a different end of tube to body connection than mine.... but anyway
is the suggestion that I lift from the top(engine rig needed) and lower or is it possible to support from underneath and lower it down.
I already have a 2 1/2 Ton trolley jack. Any thought and observations ?

Regards


Dave

The best way to do it is to lower it onto the ground onto some cardboard, jack the van up and then slide the engine out.

I always lower the engine using an engine hoist - but I have heard of people using jacks. I imagine ratchet straps would be useful too.

Someone will be along soon...

Good luck

Ringo

Here is what i did to remove the 1.6d engine.Jacked up the rear of the van on axle stands on the rear cross members.Trolly jack under the sump with a sheet of plywood between.This bit is important tie up the gearbox to stop it dropping down when attempting to pull away and lowering the engine to the ground.This can be done by roping around the bellhousing & help with an other trolly jack under it protected with plywood.Idea being you are in control when the engine is pulled out of the clutch splines and not the weight of the gearbox against it.Others on here will have there own method and can advice you.But i like to remove as much off the engine and bay so it dont interefere on removal.I took off the exhaust system & manifolds and the oil filler tube.Once you get it off the gearbox it a case then of lowering the engine down on the trolly jack a sheet of cardboard on the ground where the jack is can help you slide the engine away from the van.

Hi ringo and camper,

Many thanks for that. I have a pair of ramps which are adjustable in height, so I can set the rear of the van at what I want it to before I start and even
adjust its height a little on the way should I wish to do it.

I shall remove what I can before starting.


Thanks again

Regards


Dave

Sorted then! I only remove the exhaust, alternator and water header tank behind the number plate. That gives plenty of room.

Ringo

Here ya go. Nice bit of 4X2 across the engine hatch, sit your trolley jack on it fully up, the wheels sit either side of the timber, ratchet strap over the jack (I actually use 2 jacks and 2 straps) firmly tied to or around engine, remove all the bolts and lower to the ground onto a bit of ply and slide it out. You may have to lower it in 2 bites, depending on the lift your jacks give. Put the 1Y back the same way and with the 2 jacks side by side you can raise them independantly and tilt the engine to suit.
Good job to do on Christmas day after the turkey.
Good luck, I hope all goes well however you do it. Some on here have done it quite a few times........... Ring ring

Why didnt i think of that Pete!

Have you ever nearly lost the jack? (ie tilted over when loaded with the engine)...

Ringo

Beg, steal, borow or hire an engine crane. Thats how i did mine , but i removed as much as possible before dropping it as well. Already had the van on axle stands and dropped engine onto some wood to just pull out from underneath. I wouldnt do it with a jack unless i had a couple of people to help support he engine when lowering and removing.

ringo wrote:Why didnt i think of that Pete!

Have you ever nearly lost the jack? (ie tilted over when loaded with the engine)...

Ringo

No Ringo, I set the straps over the jack "plates" and keep as direct a lift as possible. I think if your doing it on your own this is safer than having the jack under the engine. BUT like the previous post says, beg steal or borrow a hoist..........not as much fun though.
All the best.

Hi and a Merry Christmas to you all.

I am inclined to lower it using a rig, since I'm on my own and I reckon it's safer.
I've been taking things off the 1.6D today, and having a mooch around.

Am I correct in saying that once the engine is supported, I can take out the large bolts going horizintally through the
rubber engine mount which are roughly in the middle of the tubes going from front to back, and therefore the tubes can be left in situ ?

It's strange about this that the Wiki has no details re Diesel engine removal, the photos in Bentley show the ends of the tubes connected to the body by metalastik bushes.

What do you reckon chaps ?

Regards


Dave

Yes you can remove the bolts through the engine mounts.The tube engine mounting frame does not need removing.Just ensure the sump is well supported if using a trolly jack to lower the engine.Good luck.

Is it out yet mate ? As a matter of interest where abouts are you ? (Just a nosey question really)

Hi,

I'm located in the West Midlands, to the West of Birmingham.

I have a few things to do such as an oil drain off, and a tidy up of the back of the garage before I make a move.

Regards, and thanks - will report back here once it is finished.

Dave

I always remove the one large bolt in the rubber mount on the oil filter side of the engine - and remove the whole bar from the manifold side as it gives you a lot more room to play with. Its only six bolts and well worth the effort IMHO.

Good luck

Ringo

Hi All,

The old 1.6D is out. and resting in the back of the garage. No real problems all the advice given was used
and no real snags. I have some questions though which I will list below :-

(1)The 1Y came without alternator and multi ribbed belt (looking at the pulleys), together with I am guessing some form of adjuster. Does anyone know which vehicle I can spec the alternator and belt from. The local dismantler seems to have some petrol golfs, but I am guessing I am looking for a 1.9 Diesel Golf Mk III ?

(2)Should the 1.6D flywheel be taken off and exchanged for the one on the 1Y ? They actually look different in that the 1Y
flyheel has a largish chamfer. It Looks like I shall put on a new clutch either way.


Any thoughts ?

Regards


Dave