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CU Engine Removal Help.
Posted: 20 Jun 2018, 20:37
by Andyroo
I've searched the forum, youtube etc. and can't find any steps detailing the removal of a CU engine.
I'm following the Haynes manual and it's a bit vague when I've never done it before.
I'm planning to remove the engine at the weekend but there are a few things I'm not sure about.
I've removed the wiring, vacuum hose, throttle etc, heaters and the two tin plates nearest the bumper.
I've looked at the two bolts on the top end of the crankcase. Does one also hold the starter on?
Where should I place the jack on the engine?
Am I reading it right that I need to lower the engine and gearbox together 80mm before separating them?
I'd appreciate some help on jacking the van, loosening the bolts etc. onwards. I don't want to crack/damage something, obviously.
Cheers,
Andy.
Re: CU Engine Removal Help.
Posted: 20 Jun 2018, 21:29
by 937carrera
I haven't dropped a CU either, but done plenty of other Aircooled stuff, my approach: drop the engine and box complete, withdraw and separate later, you'll need to disconnect clutch cable, gear linkage, starter cables, CV joints (can be a pain if rusty and you don't have good tools), electrics, fuel lines and ducting for heating from heat exchangers..
Do you have a decent trolley jack, use pads / wood to protect the crankcase / bellhousing, and another pair of hands / eyes will be a big help ?
I bought some wooden dollies from I think it was Wilko recently, take 200kg each, great for balancing an engine when you are moving it by yourself, £12 each
Starter is held on using one of the engine to gearbox bolts. Fiddly to get to on an Aircooled, easy on a WBX
Re: CU Engine Removal Help.
Posted: 21 Jun 2018, 06:11
by george2490
https://youtu.be/JGC3EZXa644" onclick="window.open(this.href);return false;
Exactly same as this.
Sent from my SM-A320FL using Tapatalk
Re: CU Engine Removal Help.
Posted: 21 Jun 2018, 18:11
by sarran1955
Hello,
Looks familiar....
Maybe my engine goes in next week..
so as Mr Haynes says, reassembly is the reverse of the above procedure...
Cordialement,
Re: CU Engine Removal Help.
Posted: 21 Jun 2018, 20:10
by Andyroo
Thanks everyone.
I'd already seen that video on Youtube, thanks for letting me know that the 1.6 and 2.0 follow the same procedure.
Hopefully I won't mess it up.
Re: CU Engine Removal Help.
Posted: 21 Jun 2018, 20:57
by george2490
John's Video was what I used.
Makes the whole process very simple.
I would rather drop the engine for most jobs that need that little bit extra access.
Whole process takes ten minutes, putting it back is a little bit longer if you don't get the angle right to mate the box to the engine.
Re: CU Engine Removal Help.
Posted: 21 Jun 2018, 21:28
by Andyroo
10 minutes?
I've a feeling it me take me a bit longer. At least the first time anyway.
I just hope the bolts come loose ok and not shear off like most of the others I removed so far from the van.
Thanks again George.
Andy.
Re: CU Engine Removal Help.
Posted: 22 Jun 2018, 10:47
by sarran1955
Hello,
sarran1955 wrote:Hello,
Seem to have the Flikr mastered for now.....
So as so many threads lost their photos, I thought I would recap for any newer members...
I'm getting too old to struggle, so here is my easy engine out...
The CT in all it's glory with the lifting chains in place:
]
The jack and engine hoist are in place, note the smooth rolling, clean plastic work surface:
]
The jack is to make removing the engine carrier 'surprise free',
Then as the engine is lowered to horizontal, the gearbox axle stand goes in place:
]
Now the top bolts can be loosened easily, especially the starter motor 'D' bolt
]
So now the hydraulic engine hoist loads the motor into the trailer, and so up to the workshop:
]
[
Then drive into the workshop and lift the engine onto it's 'servante' with the winch...
]
[
All of this achieved with 'No Unpleasant Bending'.........
Beer break time..
]
[
Air cooled bliss...
Cordialement,
The whole engine out 'thing' takes me 50 mins..
Wear eye protection, and spend some time preparing by releasing the cables to the heat exchangers, (if they're there and not just wired open..
), and remove /replace the crusty jubilee type clips on the flexy heater hoses
Releasing fluid on the rear engine mount bolts will not do any harm..
The engine weighs about 150 kgs whole..
Hope this helps..
Air-cooled Bliss..
Cordialement,
Re: CU Engine Removal Help.
Posted: 23 Jun 2018, 22:57
by Andyroo
Thanks everyone. Engine is out. [GRINNING FACE WITH SMILING EYES]
No real issues, though it did take me almost 2 hours. I got one of those Wilko dolly's. Excellent for £13. I didn't remove the gearbox, just seperated from the engine.
Cheers.