1.9 water-cooled engine removal hints

[doenut82]

I'm going to remove my 1.9 water cooled engine out my van, is there anything I should be wary of ?
Thanks, Adam.

[pandp38]

It may sound obvious but drain off all fluids before taking any hoses off..
Make a note of where all pipes/wires go..
Take plenty of photos

[kevtherev]

A VW engine will drop out without removal of anything (carbs, alt, exhaust etc)
But if it makes removal easier for you take it off.
There are two ways to do it, gearbox + engine, or just engine slid off the final drive spigot. (gearbox separation)
don't forget to disconnect the gearbox linkage.
Take your time.
clean the carb before you remove it (when it's out)

[IndigoSteve]

Good luck. You are braver than me !!

[ghost123uk]

When ready to drop and remove the motor, watch out for the oil filler tube. I broke mine (years ago) when it it got caught up with some rear bodywork (unnoticed by me ). Also, if leaving the gearbox in place, take care not to let the motor "hang" on the gearbox input shaft, doing that can damage the clutch centre plate (I avoided that one )

[itchyfeet]

Get the van up on ramps you can jack it and lower on to them, place one in each direction so it can't roll off
The safest way to support the van IMO.
large fence post across the hatch and then ratchet straps around the manufold.
this also alows you to slide the fence post across hatch hole if you are leaving box in place.
use straps to lower to ground in stages, place blocks or jack under engine and remove one by one so it can't drop suddenly on the straps

[Ian Hulley]

Watch the clutch slave cylinder pipe/hose and also the thermostat housing .... battery terminals off obviously, starter cables and also the gear linkage (take a photo of that BEFORE you disconnect it so you get it the right side of the mountings) Oh and don't forget the hose that goes from behind the big water pipe to the heater

Ian

[doenut82]

Thanks guys , really appreciate the info. I'm going to separate the engine from the box and a friend has kindly offered to lend me his engine stand and hoist so fingers crossed all go's well this weekend.

[ghost123uk]

What needs doing to yours?

[doenut82]

Originally it was just a exhaust replacement and full service then one stud snapped off in the head and now left with only the option of drilling it out, one pipe still seized on so I'm going to pull the block out and do all the cooling system and rebuild the carb while I'm there .

[ghost123uk]

I'm guessing you know about the thin wall at the dead end of some of the exhaust stud holes. Don't drill any deeper than standard (by mistake) or you'll be into the water jacket. Good luck with it.

[Ian Hulley]

a friend has kindly offered to lend me his engine stand and hoist so fingers crossed all go's well this weekend.

Think again ... you wont be able to lift it out. They drop out the bottom and back'rds

Ian

[doenut82]

a friend has kindly offered to lend me his engine stand and hoist so fingers crossed all go's well this weekend.

Think again ... you wont be able to lift it out. They drop out the bottom and back'rds

Ian

Only using the lift to lower it down and then to lift it up to put it on the stand .

[doenut82]

I'm guessing you know about the thin wall at the dead end of some of the exhaust stud holes. Don't drill any deeper than standard (by mistake) or you'll be into the water jacket. Good luck with it.

It's the top stud behind the water pump and thermostat, hoping to only drill half way in and use an screw extractor .

[ghost123uk]

Ah, then be very careful not to break the (brittle) screw extractor
If you do manage to break it, they are then a devil to get out.
Have you considered the "drill, in stages, to the size of the shank of the bolt, then pull the threads out like a spring" technique?
Guessing it's listed in more detail in our "wiki" here = http://wiki.club8090.co.uk/index.php/Te ... bolts/nuts" onclick="window.open(this.href);return false;