Date:         Thu, 6 Dec 2001 12:05:21 -0800
Reply-To:     Dan Snow <dieselvanagon@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dan Snow <dieselvanagon@HOTMAIL.COM>
Subject:      Re: Dan's Diesel Rebuild Part 9
Content-Type: text/plain; format=flowed

In the last installment, we completed the build of the 1.6 NA dasher engine
that was destined to be installed in the Vanagon.

I stripped off all of the engine accessories—the injection pump, water pump,
throttle and cold start cables, and the oil cooler.

I went to Ace Hardware and purchased a $5.00 sawhorse bracket kit. I made a
sawhorse out of scrap 2X4 boards that straddles the engine compartment in
the van. I looped some strong rope around the top of it a few times and hung
the borrowed chain hoist from it.  I tied more lengths of the rope to the
motor mount and to two head bolts. Then (my coupe de grace) I got a 4X4 that
spanned the whole engine compartment, and I tied a rope to it, wrapped it
down around the transmission, and back up to the board. I did this a few
times, tightening every time, so that the transmission was fully supported
by this board.

I hoisted up on the engine to take pressure off of the mounting bolts, and
when I was convinced that the engine was supported, I loosened all of the
bolts holding the engine to the transmission. The one up by the clutch
master cylinder was a little tough, but with my homemade impact wrench
(framing hammer and ratchet) I finally got it loose. It think the inbred PO
tightened all of the fasteners on this van with a breaker bar and loc-tite.

I left the motor mounts on, but removed the nuts that attache them to the
engine cradle. With some swearing and jiggling and messing with the hoist, I
pulled the engine away from the tranny. In retrospect, I think it might be
possible to ease this job by having a helper push the clutch (comments?).

I dropped the engine down onto a piece of carpet, and had to jack up the van
a little to pull out the engine on the carpet.  I stripped the other things
I needed, like the flywheel and clutch, and set the engine aside (hidden in
the bushes).

That’s all for now. The new engine was sitting in my van waiting to be put
in, and it sat for another week or two…


Daniel Snow

'82 Vanagon Diesel
'78 Puch Maxi Luxe Moped
'01 Xootr Scooter
http://faculty.haas.berkeley.edu/snow/vanagon/vanagon.html


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