Club 80-90 Forums

Alright. i know i should have put this in the tech forum but i need advice now i'm attempting to remove a 2ltr Aircooled in the morning and without a manual it will take me all weekend could someone please post or e-mail how i should go about getting the engine out kev

mate, im no expert, but i reckon the hardest part of removing an a/c is all the tinware and air duct thingies. go for it, the suns out tomorrow. what have you to lose?? you might save about £300 for the local so called mechanics to do it !!!!

dont quote me on this im a welder, but ive worked on a few of these.
as i remember

tinware off

wiring off the alternator etc

disconnect fuel lines

disconnect accelerator cable

plastic heater pipes from exchangers off

bell housing 17mm bolts

we would tend to support the engine on a jack and jiggle it out by pulling the exhaust till the clutch etc is clear then drop the jack and raise the ramp

if you dont have a ramp you could lift the van 1st, then start work, or drop the lump , jack the van and pull the engine out.

i think thats it.......................

dug - a man i like. A bombastic approach to engine removal. Makes you laugh seeing Haynes running a T25 up ramps. The fun bit comes when you come to putting it back - trying to line up the input shaft so its square and also getting the engine back on the jack.

Bombastic approach to putting engine back:

Jack van up again - grunt engine back underneath. Jack van down. Good way is to sit on your butt and use your legs to shove it more or less under the engine bay. gradually jack each side of the engine up a bit of a time on short lengths of wood, each side in turn until you can get a trolley jack more or less under centre of the sump then pump her up - watching the input shaft in gearbox (thats the bit in the middle that sticks out) doesn't foul your clutch. Ease the engine on to the gearbox input shaft, turning the engine pulley as needed to help line up the splines (correct angle helps too). Bolt her up (carefully), replumb and there ya go:)

Alternatively, studiously study the Haynes Manual, word for word, wear nice clean overalls (preferably white), run the van up ramps and discover your trolley jack won't reach high enough.....

Seriously though, most of us all learnt from Haynes but hands on experience teaches you all kinds of tricks that Haynes never mention. Oh, when you disconnect fuel line, have a suitable bolt handy to plug the line or you'll stink your house out when you go indoors:)

you want to see me change a clutch!!

[/quote]Oh, when you disconnect fuel line, have a suitable bolt handy to plug the line or you'll stink your house out when you go indoors:)

doest half sting the arm pits too

Could you imagine us as a team?

"Wheres this van you want doin' then mate? Jack? wot jack? We use a ten foot pole to lever the van over the engine using the wheel arches as a leverage point"

There is a valid point here of course. With ANY VW, always make sure YOU are the boss and not the vehicle, that way you get things done a lot quicker.