Process of rebuild, replacing heads, new exhaust & misc 1977 FI

[Jetfxr69]

[SGKent]

[SGKent]

January 13, 2020. MDX being detailed today, thought I would work on the bus for while and get the rest of the engine pulled out.

1. Remove throttle cable

2. Cut wire tie holding oil temp wire

3. Remove fuel lines

4. Release fuel like clip

5. Put round block of wood w/ small bolt into jack, put bolt into hole in trans bottom.

6. Loosen trans nose bolts

7. Loosen 4 engine carrier bolts but do not pull bolts as they support engine.

8. Remove exhaust cat, muffler etc to give more room to move engine back the put atv jack under engine.

9. Trans lowered as engine moves down and out.

10. Engine and trans out on the two jacks. easy to roll on the concrete. When you pull the engine on the atv jack, the trans follows along. There are twp holes in the plywood that the engine carrier studs and nuts drop into, and the bolt and wood plate holds the trans to the trailing jack. This way everything follows along. Neat.

11. Rolled over to workbench and ready to disassemble.

12. Detailers are done with MDX, The VW engine and trans are ready for the next phase. New heads and case. Hope my back holds up.

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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[SGKent]

Jan 20 2020

HVAC guys are here making a mod to the ducting system I engineered to lower air resistance in the system to allow better air conditioning filters, so it was a good time to remove the trans from the engine, and get the new engine case unpacked (again). Now there is room to walk thru the garage again.

Before -

after -

Remove lower starter nut, remove D bolt nut, remove lower transmission nuts, remove transmission by sliding carefully out of clutch and off engine.

_________________
"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[71whitewesty]

Boy everything sure looks nice and clean! How many miles on this engine? If I followed along correctly, this engine is just fine but you want to put a new one it with better heads and a new case etc to more or less make it as perfect as you can? Where did you find the new case?
I'll enjoy this thread as I know you will do everything with no expense spared and a high standard of workmanship. Nice to see some progress on it.
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71 Westy 1600 DP, all stock Bus 1
1970's Snow Trac 1600 SP (sold 12/2016)
1968 Tucker sno cat, sold 2021
1969 Tucker Sno cat 542
2017 VW Alltrac
71 tin top stock 1600 DP (project but runs)
Twin 71 White Westy, Bus 2, that I pulled from a 15 year slumber in a dry eastern WA field in 2015.
1966 Sundial Camper "Boomer"

[SGKent]

[TomWesty]

Glad you got your case finally.
_________________
If you haven't bled on them, you haven't worked on them.
Visit: www.tomcoryell.com and check out my music!

[SGKent]

[TomWesty]

Too bad I’m not in NorCal. I’d trade out drywall repair for getting my engine running properly.
_________________
If you haven't bled on them, you haven't worked on them.
Visit: www.tomcoryell.com and check out my music!

[SGKent]

[Bleyseng]

[SGKent]

[SGKent]

Moving to rebuild engine and replace heads. I don't have to split the case but I may split the case to replace it with the new one. Haven't decided yet. New case is ready to go. One question is always, "Do I have a cam gear that a new case will need to get the lash right... ."

May 11, 2020 Put the engine up on engine stand. Pulled clutch and flywheel. Expected the case to be wet around main seal but it wasn't. That said, always check end play before disassembly. Holding at .004". Everything has already been marked for assembly to keep balance correct so no need to mark again. Otherwise mark everything. Use engine lift to put on stand and block front to help reduce weight on flanges until some items removed.

Flywheel lock - had this since my 1971 bay. It's like 45 - 50 years old now. Best style out there. Just think - I was married and a young man in my mid 20's when I bought this. (same on the run out gauge too).

Clutch and pressure plate off. Remove bolts a little at a time so not to warp pressure plate.

Flywheel

Measuring end play before removing flywheel. Holding steady at .004".

Clevis tool I use to hook chain to engine

Where it goes on front

Lifting engine to stand. Using a hydraulic lift, HF brand. Works well. Had to add a piece of steel tubing between frame and wheel so engine stand will roll under it. Put yoke on before lifting then slide into engine stand.

Blocked front to reduce weight on engine flange.

Back side with yoke mounted. I am selling spare parts in Classifieds as I don't need them. When the bus is gone someone will get a heck of a deal on an engine lift and engine stand that work really well together for all types of car engines.

_________________
"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[SGKent]

Tuesday May 12, 2020

Remove JTube, Cross tube, heat exchangers and EGR

Photos of hoses - and remove

Photos of tin and remove front tin. Only casualty is tabs on heat shield were broken. Will have to have those welded. I have another NOS one but it is slightly shorter on the right side.

Remove injectors and injector rails

Photos of and removing runners

Electrical CSV and AUX etc gets removed.

Plenum removal, connectors and wires around plenum. End of 90 minutes work today

_________________
"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[ivwshane]

Still looks good!

Are you going to be upgrading to gee bee hoses on this rebuild or are you going for as close to stock as possible?

When do we get to see pics of your new exhaust setup:D
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77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[daves_ale]

Bookmarked and watching, great photos and will be an excellent resource.
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"Beer is proof that God loves us and wishes us to be happy"- Ben

'66 Euro Beetle 1200A
'71 Single Cab
'78 Westy
'02 Jaguar XK8 convertible

[ImAddicted]

[SGKent]

Thanks for the comments. It has lost its shine but it is still a nice engine. Gee they are small engines for such a large car. As you go thru the photos you will see a alternator bracket that is broken. I suspect this happened early after the last build. I had taken the fan apart 12 years ago to paint it (a no-no) and the belt hopped causing quite a bit of vibration. Mark was kind enough to center it for me. I think he put in about 12 - 14 hours on a lathe spinning it and trying to get it back to center. Now the belt runs very true but my guess is that it was during the period it hopped a lot that the bracket vibrated itself to death.

Remove sensors and ground

PCV

Start on tin screws 1-2 side

Thermostat removal (and oil pressure sensor)

Spark Plug Wire loom holder removal

1-2 tin and alternator wires

3-4 tin

Alternator

Side tin

Fan and shroud

Engine Mount

END OF MAY 19

_________________
"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[ivwshane]

What is this?

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77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[SGKent]