Engine back into My beetle.. Very difficult this time..

[68autobug]

Well,
I put My engine back in using the vW engine trolley and a trolley jack
and the engine went into place very easily..
done up the two bottom bolts
and then the RHS top Nut with difficulty.. [onto the D headed bolt]

then I had some chest pain and ended up in Hospital for two days
hooked up to heart monitoring machines...
and lots of blood thinning injections... Ouch..
plus they took so much blood , I thought I'd need it topped up   

  but it seems like it was VW chest pain syndrome...

Back home I finally got the nut onto the top LHS D headed bolt

then i remembered I had loosened the two ATF banjo bolts on the gearbox.. [hoses]
to get a spanner onto these two bolts I had to undo the front plate and the doghouse air vent
and move the front plate so the spanner could fit up there while I tightened the banjo bolts up.

I put the engine in with the heater boxes installed this time which was a mistake..
also the front plate bolted in which meant I couldn't see the ends of the top D Bolts..
and the doghouse air vent , which meant i couldn't get My hand down to the nut..

I filled the engine with oil and the ATF tank with ATF fluid and turned the engine over by hand [about 20 times]
with the spark plugs removed
hopefully the oil and ATF has circulated, so everything will be lubricated when i hit the starter motor..
once i find where all the electrical wires go to..
I did have some of them marked using masking tape, which fell off due to high temperatures
and being in the sun...  I eventually pushed the car out of the sun.. [in a carport]

Lee

[68autobug]

I have to bolt the flexplate to the Torque converter
with the heater boxes in place...\
not sure whether this can be done..

but i'll soon find out..

Lee

[hercdriver]

Lee,

 It looks great in the new colors. I envy you for having your motor to this stage. I can't wait to get mine back from the shop at the end of the month. I can't say I took the time to label wires though. Many were already disconnected before I got to the car. So I'll have to rely on pictures and the Bently manual.

 Chest pains?  I hope you're feeling better. That sounds serious. Don't over do it before you know what's  going on.

Dave

[68autobug]

Thanks Dave,
I'm taking it easy at the moment but I want to go to a VW show 200kms away
on Easter saturday, so I want to have the car running
to make sure everything is OK... [fingers crossed]

I rewired My car so the colors are all wrong... lol
then i added a high energy ignition system which has 3 or 4 wires..
so there are a few to find out what they are...
I should mark each terminal...

I have never seen a beetle engine with the heater hoses painted..
so I may start a new craze...   

Best of luck with your engine..

Lee

http://community.webshots.com/user/vw68autobug

[greenghia]

Hey Lee,  Good to hear you are doing better.  I have always removed/installed my engines with the heater boxes installed. Never even thought to remove them while in the car. Funny how we get into a pattern with these things. No problems installing the converter bolts, just be careful not to drop them in the bell housing.  Hope you make it to the Easter thing.

[68autobug]

Hi Green,
Yes I've been under the car again this morning,
the reason I really took the heater boxes off
was I went to install the two pieces of tinware that fit under the pushrod tubes..
I had the bolts in the heater boxes
when I saw I couldn't fit the tinware... 

I've now made a few notes...

Biggest problem is My memory...
due to medical problems [up there]

Ive had the engine in and out so many times, but...
it was always in a short space of time...

now after driving it for a couple of years..
My old brain was a bit rusty..

so, basically, it looks like I can install a complete engine
with heater boxes and all tinware in...

as you know its much easier to do these things with the engine out..

so I'm slowly getting there
and hoping all will be OK for the trip to Sydney at Easter
which is over 200 KMS away from Me...
My Son and 3 others will be travelling down together...

cheers
and thanks for the well wishes..

Lee

[greenghia]

Hi Lee,    Yep the only things that are off my engines when I remove/install them are the rear tin, muffler, alternator pulley and torque converter. I find few things more frustrating than dirt/rust falling in my eyes while laying under a car. I'd put the sad face emoticon here but it wont let me.  Let us know when you get it worked out.

[68autobug]

Well Greenghia
I have the front tin piece finally in place...
I've found it doesn't fit neat onto the single port tinware..
so, I've filled all the gaps etc...
now fighting with the doghouse oil cooler extractor screw...
then the top piece to go on [doghouse piece..]
then put the heaters back on
and then i can start it...

and Now summer has just arrived with 36.5C here today
and I thought it was all gone...  lol..

and the sun is moving daily onto the rear of My car...
I picked up a screwdriver a while ago.. [one with metal thru to the top]
and it kept burning My hands...

cheers

LEE

  I'm nearly there...  I'm nearly there...   [/b]

[68autobug]

I had My engine running for a few minutes...
and found between the cylinder and the head on number 1 & 2
is leaking... more like spraying oil over the pushrod tubes..

wasn't much oil...  it didn't drip
its lucky I saw it on the pushrod tubes...

I can now see that the head isn't on straight..
thats why its leaking..

I did notice the cylinder going in crooked,
so i undid all the nuts and did it again...
to VW manual specs and sequence.....

I've spoken to a few VW owners who never do the heads up
in the VW sequence without any problems.....


so, I will Not be driving My car to the BUG IN 180kms away..
on easter saturday...
           
I am also going to make some modifications to My engine..
I'm taking the doghouse oil cooler out of the fan shroud and placing it
outside of the engine bay...
I will then modify the fan housing , so all the cooling air will go over the
cylinders and heads..

cheers

Lee


http://community.webshots.com/user/vw68autobug