Assembling engine in-car

[cjmck422]

1. Remove old engine


2. Istall short block assembly to transmission without the head studs

3. At this point install connecting rods, bearings, torque to spec

4. Next install the pistons with rings
5. Then using piston ring compressor, install the piston sleeves
6. Next using a stud installer/remover install only the upper head studs
7. At this point you can slide the cylinder heads on from underneath, it wil be necessary to tilt the heads to clear the studs
8. Now install the pushrod tubes and seals, then the lower head studs (for the rear-most lower head stud on the #2 cylinder it is necessary to drill a hole through the r/r inner fender to pass the head stud through to the engine case)
9. Next, all the nuts and washers for the head studs, torque to spec

10. Install the pushrods and rocker shaft assemblies, adjust valves to spec
11. Install valve covers and gaskets


12. Instal remaining external components
13. Install exhaust
14. The finished product

[Bookwus]

Hiya cjm,

I've been puttering around VWs for the better part of thirty years and this is the first time I've seen this approach.  Imaginative improvisation!

Very clever and one cannot quibble with the end result.  However, it has been my personal experience that some work is really quite difficult with the engine in place.  Just finding those bottom fasteners (at each side) of the fan shroud, let alone working on them is a pain.  And tightening up the manifold ends on a dual port is no fun either.  Even a simple task like removing spark plugs takes something of a contortionist.

So, I'm curious..............  why this approach?  Are you on your own without a helper?  Space and lifting limitations?  I'd really like to know why you went this way.

And, by the way.......how do you like that aluminum universal case you used?  Getting good service from it?   I am installing an engine in a few days built on an identical case.

[cjmck422]

Hey Mike, ya hit the nail right on the head, I was a one-man operation in installing this engine, no helpers, no lift, no garage, no special tools, laying flat on my back in the driveway.  Not only that, I thought it would be a good "character builder", to prove to myself it could be done, and perhaps  make me appreciate the car more when its done.  As for the engine case, the only problem I've had with it so far was it didn't include the shuffle pins for the crank bearings, so I had to order them separate, other than that its been great.  The old engine case was rotting away at the drain plate mount from the inside, the oil that I drained out of it had probably been in there so long it became corrosive.

[68autobug]

You will not find it in any VW book or manual...

You have to take the engine out to do just about anything on a VW engine

So, You have proved all the experts wrong..

what about the sealing rubber around the engine.. did you get it in OK...

Nice looking Case and pulley...

I'm with Mike, I'd rather put it together out of the engine bay..

I did mine first in a shed in the winter [Heater On]

next time... in the Dining room....
but My engines are clean and painted....lol   

last time i had it apart I just left it in the carport behind the car...

Some people wouldn't drill a hole in the body...lol   [no no not a hole...]

Great Work...

I'm going to have a problem proving to people that it can be done...
after all these years...

cheers

Lee

PS: I usually do eveything Myself Mike...
I did get my Son to help take the engine out once and back in maybe twice...

[cjmck422]

Hey Lee, i haven't got the engine seal in yet, I'm going to pull the engine out when it comes time to paint the car and at the sime time probably replace all the engine tins.  As for the drilled hole, it will be plugged up, or welded over and ground smooth before painting.  I agree, it probably would be much easier to assemble the engine out of the car, especially if I build it in the dining room....lol

[68autobug]

Hey Lee, i haven't got the engine seal in yet, I'm going to pull the engine out when it comes time to paint the car and at the sime time probably replace all the engine tins.  As for the drilled hole, it will be plugged up, or welded over and ground smooth before painting.  I agree, it probably would be much easier to assemble the engine out of the car, especially if I build it in the dining room....lol

Yes, lapping the valves in while eating Pizza isn't recommended
it takes two hands to eat a Pizza...

I just believed what was written in all the manuals...

I have taken all the tinware out while the engine was in the car- a couple of times...

If the engine didn't have all the ATF lines and hoses and vacuum hoses to undo

it wouldn't be so bad taking the engine out....

I used to dread taking the exhaust off...  I would try to think of ways getting around it...
as putting it on is a real pain....
if i didn't have the heatrisers it would be easy...
plus I have flanges on My heater boxes and muffler pipes..

but I have succeeded a few times without too much trouble...
I think its getting easier....

cheers

Lee

pS; I use the early model engine bay seal...  shaped like  I<  instead of the late model
thick rubber seal which goes hard and cracks very easily...
the early seal is shaped like a Vee - top piece goes on top of the tinware
bottom piece goes under the tineware...  Lee