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bobnorman
Samba Newfoundlander
Joined: August 09, 2010
Posts: 1389
Location: Newfoundland
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 Posted: Sun Apr 12, 2015 9:20 am Post subject: |
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| paul_round wrote: |
You really need a trolley jack to do that.
I would be really nervous using a scissor jack on a plank.
All your work so far has been wonderful, it would be tragic if anything went wrong with this approach. |
^^ Truth right there. Even a cheap one from Halford's or similar, shouldn't be anymore than 20 or 30 Pounds, will make a lot of your jobs a lot easier.
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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| Posted: Sun Apr 12, 2015 9:44 am Post subject: |
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| paul_round wrote: |
You really need a trolley jack to do that.
I would be really nervous using a scissor jack on a plank.
All your work so far has been wonderful, it would be tragic if anything went wrong with this approach. |
Ok. First thing I should say is that I'm not in the Emergency Dept, and the engine is in.
Yay!
That was really unpleasantly difficult and I think, a dangerous way to do it.
There were two reasons I used the scissor jack. It had a bigger saddle than either of my trolley jacks, and to get the engine high enough to get the trolley jack in it was worryingly high on piles of wood. I'm not going to do it like that again though, as the whole thing was unstable when raised high up, especially when the car creeper was moving underneath it all. Even the 'safety stack' of wood we had at one stage looks ridiculous in retrospect.
In short, it was a dance and a wiggle to get it up into the engine bay, and it was only when I raised the front of the car to level everything that it all slid into place. Luckily, I had a strong and capable friend to help but we were both very happy to get it finally in!
Thanks to all for advice, and I would definitely invest in an ATV jack, or a larger saddle low height trolley jack next time.
Part of the problem was that I thought I had made things easier by having the car on ramps to give workspace underneath, and to allow the engine to slide out from the car, but the downside was the nightmare getting it high enough to go back in!
You live and learn!
Since getting the engine in, I tightened the bolts as hard as I could with a ring spanner, no room for a torque wrench! Cleaned the starter terminals and put dielectric grease on, loose fitted the heat exchangers and the silencer (wished I had done that when the engine was out, but that might have been the final straw for the scissor jack! 
Having a celebratory mug of tea now, before I go back and tighten the exhaust and fit some stuff back in the engine compartment!
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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
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Bleyseng
Samba Member
Joined: July 03, 2005
Posts: 4752
Location: Seattle
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| Posted: Sun Apr 12, 2015 10:46 am Post subject: |
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Look good! Make sure there is oil in the engine before starting it.
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70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!(sold)
76 Porsche 914 2.1L L20c, 120hp Djet (sold)
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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| Posted: Sun Apr 12, 2015 2:22 pm Post subject: |
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Finished off a long weekend's progress with refitting the exhaust system. The heat exchanger bolts were so much easier to tighten when I did it the first time (out of the car!) for the top right one, the only tool I could get on it was the 10/13 spanner out of the original VW tool kit! I suspect I haven't tightened it to 2 m-kg!  when I take to the garage for its MOT annual check I'll get them to check it.
Reconnected the heater cables to the newly painted levers, and the accordion tubes...
Then spent quite a long time fitting the rest of the engine tin. I was pleased to discover that, having used new tinware screws where they're not visible and underneath, and discarded the ones with chewed up heads, I had just enough to reuse original screws in the engine bay. Sweet! 
Progress shot at the bottom, before I left the garage for a well earned hot bath!
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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
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wcfvw69 
Samba Purist
Joined: June 10, 2004
Posts: 13389
Location: Arizona
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| Posted: Sun Apr 12, 2015 4:51 pm Post subject: |
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Glad you got the engine offered back up in place. One other strong suggestion- Put a piece of masking tape or duct tape over the carb manifold where the carb goes. You don't want to have to tear the motor all apart due to something falling into it through that open hole and breaking a piston or bending a valve.
It's happened to the best of us.
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Decades of VW and VW parts restoration experience.
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**Now rebuilding throttle bodies for VW's and Porsche's**
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bobnorman
Samba Newfoundlander
Joined: August 09, 2010
Posts: 1389
Location: Newfoundland
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| Posted: Sun Apr 12, 2015 7:40 pm Post subject: |
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Hey, Great that you got it back in!  Can't wait to see it running. I remember one time having a really hard go getting it in, finally managed to get it in place, bolted it up, connected everything, put all the tins on, then noticed the throw-out bearing sitting on the corner of bench...
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Air does not freeze. Air does not boil.
http://www.thesamba.com/vw/forum/viewtopic.php?t=289807 |
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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mcdonaldneal
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Joined: June 13, 2013
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Location: Gullane, Scotland
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mcdonaldneal
Samba Member
Joined: June 13, 2013
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Location: Gullane, Scotland
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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| Posted: Mon Apr 13, 2015 10:05 am Post subject: |
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I've been beavering away since I got home today and have made some good progress!
New carb gaskets had arrived in the post, so I coated them lightly in Vaseline (which is supposed to make them easier to reuse) and fitted the carb. One less hole for things to fall down! 
Then the distributor and HT leads went on, clipping into the fan shroud, which for some reason I had never been able to do before. Nice and tidy!
Then a lot of head scratching wiring to be connected up, especially the rear window defrost relay which is just about impossible to read the terminal numbers on! 
Then filled the engine with oil and the air cleaner, and fitted the charcoal canister and hoses.
Cut new fuel hoses and clipped with Oetiker eared clamps, and replaced some of the vacuum hoses.
Battery in and connected, hope the wiring wasn't too crazy!
Last thing I want to do before I start up is to flush the hard fuel line under the car. I had cleaned it with carb cleaner, but wasn't able to get anything through to clean it out. I have my fuel filter under the tank, so I just want to be sure there isn't any crap sitting in the line. Once ive done that, might be ready to start her up.
Anything I might have forgotten?
Looking like an engine bay now!
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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
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c21darrel
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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| Posted: Mon Apr 13, 2015 12:54 pm Post subject: |
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Set up a system to flush the hard fuel line under the car. Put 5 litres of fuel in the tank. Ran the line into a funnel filled with filter paper and collected in a petrol can.
Discovered some facts...
Petrol does not flow uphill. (Levelled the car by jacking up the front!)
Fuel needs a bit of help to get going.
Carb cleaner and petrol taste disgusting.
Once I got flow going I ran ten litres through the line and looked at the filter paper. There were a few flecks of material the first time, and just a smudge of carbonaceous something the last time. I'll call it good.
Then connected the fuel line back up, and set the timing statically at zero deg to get me started. Not sure whether I'll start her up tonight or first thing tomorrow...
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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
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c21darrel
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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| Posted: Mon Apr 13, 2015 1:52 pm Post subject: |
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Well, I'm sure you can't wait, and neither could I!
As soon as Shona came home and we had eaten, I persuaded her to come out into the garage, even though it's about 7degC.
Shona eventually found the accelerator pedal, and I adjusted the cable at the carb. Then we agreed (I insisted!) that we have a quick go at starting up.
Several long turns of the starter, and pumping of the accelerator...
Nothing.
I half expected that, as the carb was empty, but thought it might catch?
Came around to the back to realise...
The distributor cap was still off from adjusting the throttle cable! 
Tried again, and fired up first time!!
Very happy, just ran it for a few seconds, but will get it off the ramps tomorrow!
http://youtu.be/PBajcnLUH2Q
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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
Stop dead photo links! Post photos to The Samba Gallery! |
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bobnorman
Samba Newfoundlander
Joined: August 09, 2010
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mcdonaldneal
Samba Member
Joined: June 13, 2013
Posts: 2649
Location: Gullane, Scotland
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| Posted: Tue Apr 14, 2015 4:33 am Post subject: |
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Shit.
Shit.
Shit.
Pride comes before a fall, and I can't believe I'm writing this! It's all so obvious in retrospect!
Got up really early this morning to do a compression check. Bit of a fiddle with the air cleaner in and everything, but got it done.
Three cylinders at 120psi and No 1 initially read 118, but then two readings of 100 and 105. Checked again at the end and got the same, 120, 105, 105.
A bit strange, but maybe because it's only just back together, could the rings need time to seat? Suggestions welcome.
Then refitted the spark plugs.
Thought I'd better check the torque in the Bentley. Big mistake. They say 3-4 kg-m. Seems a lot, thinks I, I'll go for the lower end, 3kg-m.
When I got to the one hole that doesn't have an insert, getting tight then...
A give and suddenly loose!
Should have just gone with my instinct.
I had visions of having to dismantle the engine, heads off and place another Timesert, and I swear I could have cried. So near. So far.
Removed the plug and, right enough, there were threads on it.
When I had composed myself, I rang my regular garage and chatted to the 'old school' mechanic there. Don't worry, if you can get it here we can put in an insert with the engine in, check the chamber with a camera and suction out any metal. Sounds good, but how to get there?
I gingerly screwed in the plug, checked it wasn't blowing, went for a short test drive, and decided to drive the 20 miles in to Edinburgh. Slowly, gently and praying that the plug would stay in.
The only incident was that I burned my fingers on the heat riser tubes when I was checking they were hot!  I guess I cleared them out OK then!
Have left it with the garage to put in the insert, and to do the MOT road worthiness test, and I'll pick up tomorrow.
I can't stand this roller-coaster, I want to get off!
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1978 marino yellow Bay Dormobile camper
1969 signal orange Karmann Ghia convertible
1976 martini olive Bay Dormobile camper
Stop dead photo links! Post photos to The Samba Gallery! |
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mcdonaldneal
Samba Member
Joined: June 13, 2013
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Location: Gullane, Scotland
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VWKC
Samba Member
Joined: December 04, 2012
Posts: 42
Location: Kansas City, Missouri
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| Posted: Wed Apr 15, 2015 5:58 am Post subject: |
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| This remains one of the most engaging threads I've ever had the pleasure of reading on the Samba. Looking forward to your (and your mechanic's) success. |
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Bleyseng
Samba Member
Joined: July 03, 2005
Posts: 4752
Location: Seattle
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| Posted: Wed Apr 15, 2015 6:45 am Post subject: |
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Hopefully you'll put a drop of anti-seize on the spark plug threads so you won't rip out the timeserts.
_________________
70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!(sold)
76 Porsche 914 2.1L L20c, 120hp Djet (sold)
87 Syncro Westy Titan Red 2.1L 2 knob 100k miles |
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