Club 80-90 Forums

Hi people, so my van is on ramps and i'm looking forward to removing the engine and gearbox to address some issues!

Now i've searched the forum looking for advice on engine removal/dropping, but seem to have only found advice on petrol and mostly air cooled engines!

Mine is a 1.7KY (water cooled) and i'm thinking i probably need to clamp some water and fuel hoses? I've never removed an engine before, i have no idea what undo or clamp first! So any and all advice is much appreciated!

I do however have an engine crane to take the weight and know where to connect the leveller! Guess thats a start!!

Cheers!

undo any coolant hose you like, the lower down the better for draining, if you are keeping the coolant then catch it in a bowl, if not let it drop.
As for fuel dunno somebody will, if it's not under pressure then just pull the hoses off and stick something in the pipe to stop dirt getting in, I use drill bit shanks.

itchyfeet wrote:undo any coolant hose you like, the lower down the better for draining, if you are keeping the coolant then catch it in a bowl, if not let it drop.
As for fuel dunno somebody will, if it's not under pressure then just pull the hoses off and stick something in the pipe to stop dirt getting in, I use drill bit shanks.

Cheers itchyfeet, any idea how much coolant will leak from the engine? I believe my van will contains around 14 litres (somewhere)!?

dunno at a guess 5-6 litres as that's what comes out of a WBX

itchyfeet wrote:dunno at a guess 5-6 litres as that's what comes out of a WBX

Cheers, i'll try my 2 gallon bucket and see how that does then

I use an old washing up bowl and a bucket, bucket may not fit under so decant the bowl into bucket when full.

If you’ve never taken an engine out before, the book of lies, (Haynes manual) is a cheap and sensible shout to refer to while your doing the job, read as much as you can from the internet to make sense of it all.
From a safety point of view
Chock your vehicle, it’ll be the only thing apart from the parking brake stopping it moving.
Ensure the parking brake is fully applied.
Disconnect the battery - you don’t want an inadvertent arc when doing starter/alternator
When unbolting the engine to gearbox do the bottom bolts and any connectors unberneath first - you don’t want to be underneath a half disconnected engine while your yanking on stuff, your body will not make a great cushion for a dropped engine.
When underneath wear safety specs - even a cheap pair will help prevent dust, rust, fuel, coolant, etc getting in your eyes.
Tight bolts, try to tighten a little first to crack the rust seal and use a penetrating lubricant like WD40 it makes life easier and if you round it off tightening you still have a shot at getting it off.
Have your phone to hand or make sure someone can hear if you shout for help - it takes a second for simple things to go very wrong particularly when working alone.

Thanks adie89, very much appreciate your advice.

I would not have though of tightening rusty bolts before trying to remove them? I managed to get hold of an impact wrench which should make a few removals easier too.

I will keep my phone on me if solo

re: phone.. Take loads of photos of engine bay and all round underneath.. you may not need them but it can be invaluable later on when faced with several wires and bits of coolant hose

Will do mrhutch, i was thinking of taking pictures to try and make a removal guide for a diesel engine on here. Second thoughts, I will probably make plenty of mistakes

Any luck finding that alternator??

The Hairy Camper wrote:Thanks adie89, very much appreciate your advice.

I would not have though of tightening rusty bolts before trying to remove them? I managed to get hold of an impact wrench which should make a few removals easier too.

I will keep my phone on me if solo

It seemed odd when I heard it first. But by trying to tighten it a tiny bit you’ll crack the corrosion and then be able to undo, but if it’s too tight and the tool slips and damages the fastener head you should still have the opposite direction not rounded off so you can still loosen.

Ok, so today I removed the coolant hoses (drained/collected any coolant that came out),
Disconnected and removed battery,
Disconnected any wiring connected to the alternator.

Despite feeling like i could easily mess things up, i quite enjoyed myself

I have a few questions i'm hoping someone would like to answer

First, whats this before i disconnect it:

Brake fluid reservoir? So rusty i'm thinking of replacing it??

2. Can the exhaust system stay connected when i drop the engine? Looks as if it can.

3. What threads are the CV joint bolts? My 6mm allen was close, but did not seem to fit? Bolts could just be dirty though?

Cheers!

I don't know the 1.7kY engine so can't help on the identification except that it isn't what you think it is. Follow the hose and see where it goes to.

On the CV bolts I think they will be either 6mm hex or could be an 8mm spline. You should properly clean them, soak them and then use a "tapped" in bit with a socket to remove them. Allen keys are too soft, twisty and if you chew the heads up life will become difficult.

Good luck

Its the brake servo pump.

multisi wrote:Its the brake servo pump.

I wasn't far off Am i safe to disconnect and plug this?