HI ....wow.. sounds scary .

*the exhaust system DOES NOT have to come off to remove the engine !~

Since god invented rear engine VW's ..it has *always* been like that.. the ENTIRE exhaust system just 'stays with the engine.'

naturally, you will drain the cooling system as much as you can before starting to remove the engine. That's as fundamental as taking the wheels off to work on the brakes.

I'm sure you know ...or I would sure hope THEY know to disconnect the battery as a first step. ( I doubt you have a 'code' radio ......need to watch out on some later VW's... if you see a little 'key' icon on the radio face...that means if power is disconnected...you need a 4 digit code, AND how to enter that code, to get the radio back on. But I doubt you have that. )

I hope it goes swimmingly well. they should have a torch handy to heat exhaust nuts and studs when removing the exhaust system ...from the REMOVED engine.

I'm concerned. I've seen some pathetically bogus VW work by students .. where is the instructor in all this ? I've seen a VW engine assembled by an Auto Shop Class... so it couldn't possibly work....so be careful.

Personally, I would try to enroll the instructor in being responsible that things are done right. There are ... heck, just on waterboxer clutches, I've seen them done wrong about 50 ways, and commonly too, or almost commonly.

anyway .. I'm sure you'll be asking questions a lot... as you should ! live and learn, and hopefully no lessons learned 'the hard way.' pre-fill the oil filter before firing up the new engine. be real careful adding oil to a new oil filter .. that center hole is the unfiltered side. Anything that gets in there. goes directly to the bearings.

you'all should read John Muir's Idiot's Guide.. not to learn how to work on air-cooled VW's ..but to learn 'vw think.'

here's a common newbie mistake... you start removing the engine , but you forgot to undo the throttle cable. or .. you forgot to support the transaxle and you stress the hell out of the trans input shaft.

have fun ! I suspect you are the guy who asked me about some 1.9 exhaust pipes... I had a hip operation since then and 'weather' challenges since then .. but I got some out to check out and semi-restore .....but didn't get further than that. But I still have them.

oh .....man I'm cynical today .. I'll bet the instructor doesn't even know to put 'something' like Teflon paste, or red permatex high tack on thermostat housing bolts, and water pump bolts... something to prevent corrosion of the threads..( wow, they come out beautifully years later ! ) same for spark plugs, I have yet to see a spark plug installed with anti-seize on the threads unless I did it.

tell this to the instructor .... 'It's not about the parts...it's about the WORKMANSHIP.'

good luck, let the questions begin !

Scott www.turbovans.com

----- Original Message ----- From: "A PETER MARSH" <apetermarsh@MAC.COM> To: <vanagon@GERRY.VANAGON.COM> Sent: Thursday, January 06, 2011 9:05 AM Subject: A question of ORDER

> Dear List, > > The ORDER that I question is the blow by blow removal of the 2.1 wasser > boxer in my 91 GL in away that is very easy to understand and perform. > "Why" - I hear you ask? > > My local VoTech school here in Naples has come to my rescue and will > remove my broken engine and rebuild the "new" used VW rebuilt engine I > have to install. The principals have asked that I attend each day > students will work on my project and in an effort to guide them in the > right direction - I need some direction from my experienced list friends > to make sure I don't instruct the students the wrong way! (I don't want > to screwup.) > > I know the cooling system has to be disconnected and I know the exhaust > system has to come off first - or do I? (I am only assuming this is what > happens.) > > Please jot down what you think is the correct way to remove the old engine > please. Then I need an ORDER in which to rebuild (add) all the bits to > the "new" engine before we install. The van will be on a lift. The > replacement engine on my HF engine stand. > > The school will take my Beastie the second week of February so we have > plenty of time. > > Thank you in advance > Peter Marsh > Naples FL