Date: Fri, 2 May 1997 13:58:28 PDT
From: Nick Pace <nickpace@rand.org>
Subject: VW-1600 BUS LONG BLOCK REPLACEMENT STEPS

They may be of no use to most of you but the last couple of times I did a
long block swap for my '71 Bus, I decided that I would make notes about what
I did and when.  After you have done these things often enough you can do
it in your sleep but invariably you'll put a piece of shrouding on out of
order before some sort of gizmo that should have been bolted in place
first.  My notes were to prevent this sort of thing from happening and to
remind me of what tools I needed **before** I crawled underneath the Bus.
I was looking at them today and thought that they might be of some sort of
minimal utilty to those of you contemplating your spring rebuild or for
those that have never done it before.  You'll need Muir and the shop manual
anyway but it's nice to have a third opinion.

The notes below are sort of cryptic and may not be strictly applicable to
all 1600 Bus owners.  You should know that I belong to the "pull the
bumper + rear deck-use a sissor jack on the transmission-put a floor jack
on the engine-undo the bolts and nuts-and pull the engine rearward" school
of R&R; those of you who roll the Bus itself or jack it up may not find
this applicable.  I also have done a number of things to my Bus that
speed up R&R and my personal comfort such as having the gas line extend
into the engine compartment so that I need only disconnect it from the
pump, plug it up right then with a pencil, and push it through the
firewall (I used to do this under the Bus and always hated it when the gas
ran down my arm).  I also have a funky bumper attachement that probably
exists nowhere else in the world but other than this, it should be pretty
universal.

The stuff in squigly brackets {} refer to the tools needed.  The stuff in
square brackets [] refer to the parts or gaskets to be pulled off or
replaced.  The stuff in parentheses are only explanatory.  Other than the
initial washing of the engine with spray cleaner (what a nice thing that
is!), I don't mention any cleaning or painting of the tin, checking the
starter and polishing up the contacts, fixing the side lights while the
engine is out, etc, etc.  The idea here is to get the job done in the
minimal time and be focused on the matter at hand.

Hope you can use this.  I figured that with all the fine advice I've gotten
from the newsgroups I should give something back.


Nick


 legend:
 10mm skt           = regular 10mm socket with a socket wrench
 SP skt             = spark plug socket with a socket wrench
 long FSD           = big ol' flat head screwdriver
 short FSD          = short and stubby flat head screwdriver
 medium FSD         = you figure it out
 15mm deep skt      = deep 15mm  socket with a socket wrench
 short ext          = short socket extension
 long ext           = long socket extension
 8mm wrench         = 8mm box or open wrench
 cheater pipe       = piece of pipe to be used on handle of the socket wrench
 17mm ratchet wrench=sort of like a flat box wrench but has teeth, great
                     for the starter nut inside the engine compartment
                     (about $10 from Sears), a regular 17mm wrench will
                     also work
 stubby 13mm wrench =a small and short 13mm open end wrench
 monkey wrench      =what i call a cresent wrench
 flywheel lock      =from vw stores (about $10), keeps flywheel from moving,
                     not critical but saves wear on clutch bolt threads
                     since you can use the clutch bolts and a
                     piece of iron instead
 clutch alignment   =from vw stores (about $6), not critical since you can
                     do it by eye


 * clean engine {spray engine cleaner}
 * drain oil; remove sump screen if not new long block {SP skt,10mm skt}
 * turn off heater
 * muffler ext pipe {long FSD}[clamp]
 * bumper {15mm deep skt,14mm skt,17mm skt,short ext}
 * rear guard {13mm skt,short flat SD}
 * replace oil plug&screen {SP skt,10mm skt}[plug gskt,washers,2 sump gskts]
 * battery ground strap {13mm skt}
 * turn engine to #1 TDC {SP skt}
 * air cleaner {long FSD}
 * generator wires (d+, d-, and ground) {8mm wrench,short FSD}
 * detach wiring harness (ignition, oil press, head temp)
 * detach backup light wires [fuse]
 * detach spark plug wires (leave in dist cap)
 * accelerator wire connection {8mm wrench}[connector]
 * gas line to pump, plug+push to left {medium FSD,pencil}
 * brake booster line+valve {short FSD}
 * sissors jack under trans {sissors jack}
 * floor jack under oil sump {floor jack}
 * under left: top left engine bolt {17mm skt,long ext,cheater pipe}
 * under left: left side heater cable and detach tube {long FSD}
 * under left: pull accel. cable through (optional)
 * under left: pull gas line through (optional)
 * under left: bottom left engine nut {17mm skt,short ext,cheater pipe}
 * starter bolt nut {17mm ratchet wrench}
 * under right: right side heater cable and detach tube {long FSD}
 * under right: bottom right engine nut {17mm skt,short ext,cheater pipe}
 * rear carrier to body bolts {15mm skt,short ext}
 * pull engine
 * confirm engine at #1 TDC {SP skt}
 * install flywheel lock
 * remove dip stick
 * head sensor {medium FSD}
 * dist cap and wires {long FSD}
 * carb (w/ gas line to pump) {13mm wrench}[gskt]
 * accelerator line tube
 * air tubes to heater tin connectors
 * fan belt {SP skt,short FSD}[rings,belt]
 * generator strap {13mm wrench,13mm skt}
 * generator and fan housing {10mm wrench,10mm skt,long ext,long FSD}
 * fuel pump (w/ line to carb) {13mm skt,long ext}[2 gskts]
 * cylinder shrouding screws next to intake manifolds {long FSD}
 * intake manifold boot clamps {long FSD}[four clamps]
 * intake manifold center unit nut {13mm skt,long ext}
 * heat riser cover {long FSD}
 * rear upper engine shroud {long FSD}
 * heater connectors {long FSD}
 * heat riser bolts {10mm wrench,10mm skt,long ext}[2 gskts]
 * muffler+resonator from heater boxes {11mm wrench,11mm skt}[2 clamps&gskts]
 * front upper shroud {long FSD}
 * intake manifold & heat riser assembly {13mm skt,long ext}[4 gskts]
 * oil filler assembly {13mm wrench,13mm skt,long ext}[3 gskts]
 * two rear air deflectors {long FSD}
 * cylinder shrouds (w/o screws next to intake manifold) {long FSD}
 * oil cooler assembly {stubby 13mm wrench;10mm if base}[2 gskts;4 if base]
 * shroud screws on right side heater box {short FSD}
 * right side heater box {13mm wrench}[2 gskts]
 * right side under-cylinder shrouds {long FSD}
 * shroud screws on left side heater box {short FSD}
 * left side heater box {13mm wrench}[2 gskts]
 * left side under-cylinder shrouds {long FSD}
 * clutch mechanism {13mm skt,torque wrench,flywheel lock}[clutch]
 * crankshaft pully {big monkey wrench,puller}
 * pully key [key]
 * rear lower pully shroud {long FSD}
 * rear engine carrier {13mm skt,short ext}
 * distributor, mark position {11mm wrench,long FSD}[rubber ring]
 * spark plugs {SP wrench, long ext}
 * oil sender {med monkey wrench}[gskt]
 * remove flywheel lock
 -----new long block-----
 * oil sender {med monkey wrench}[gskt]
 * spark plugs {SP wrench, long ext}
 * check position of engine for #1 TDC
 * apply flywheel lock
 * distributor {11mm wrench,long FSD}[rubber ring]
 * rear engine carrier {13mm skt,short ext}
 * rear lower pully shroud {long FSD}
 * pully key [key]
 * crankshaft pully {big monkey wrench}
 * clutch mechanism {13mm skt,torque wrench,clutch alignment tool}[clutch]
 * left side under-cylinder shrouds {long FSD}
 * left side heater box {13mm wrench}[2 gskts]
 * shroud screws on left side heater box {short FSD}
 * right side under-cylinder shrouds {long FSD}
 * right side heater box {13mm wrench}[2 gskts]
 * shroud screws on right side heater box {short FSD}
 * oil cooler assembly {stubby 13mm wrench;10mm skt}[2 gskts;4 if base]
 * cylinder shrouds (w/o screws next to intake manifold) {long FSD}
 * two rear air deflectors {long FSD}
 * oil filler assembly {13mm wrench,13mm skt,long ext}[3 gskts]
 * intake manifold & heat riser assembly {13mm skt,long ext}[4 gskts]
 * front upper shroud {long FSD}
 * muffler+resonator from heater boxes {11mm wrench,11mm skt}[2 clamps&gskts]
 * heat riser bolts {10mm wrench,10mm skt,long ext}[2 gskts]
 * heater connectors {long FSD}
 * rear upper engine shroud {long FSD}
 * heat riser cover {long FSD}
 * intake manifold center unit nut {13mm skt,long ext}
 * intake manifold boot clamps {long FSD}[four clamps]
 * cylinder shrouding screws next to intake manifolds {long FSD}
 * fuel pump (w/ line to carb) {13mm skt,long ext}[2 gskts]
 * generator and fan housing {10mm wrench,10mm skt,long ext,long FSD}
 * generator strap {13mm wrench,13mm skt}
 * fan belt {SP skt,short FSD}[rings,belt]
 * air tubes to heater tin connectors
 * accelerator line tube
 * carb (w/ gas line to pump) {13mm wrench}[gskt]
 * dist cap and wires {long FSD}
 * head sensor {medium FSD}
 * replace dip stick
 * remove flywheel lock
 * push engine in part way
 * push through gas line and accelerator line
 * insert engine
 * start bottom right engine nut {17mm skt,short ext,cheater pipe}
 * remove sissors jack under trans
 * under right: bottom right engine nut {17mm skt,short ext,cheater pipe}
 * under right: right side heater cable and detach tube {long FSD}
 * starter bolt nut {17mm ratchet wrench}
 * under left: bottom left engine nut {17mm skt,short ext,cheater pipe}
 * under left: pull gas line through
 * under left: pull accel. cable through
 * under left: left side heater cable and detach tube {long FSD}
 * under left: top left engine bolt {17mm skt,long ext,cheater pipe}
 * rear carrier to body bolts {15mm skt,short ext}
 * remove floor jack under oil sump
 * brake booster line+valve {short FSD}
 * gas line to pump, make sure filter is off of manifold {medium FSD}
 * accelerator wire connection {8mm wrench}[connector]
 * reattach spark plug wires
 * reattach backup light wires [fuse]
 * reattach wiring harness (ignition, oil press, head temp)
 * generator wires (d+, d-, and ground) {8mm wrench,short FSD}
 * air cleaner {long FSD}
 * battery ground strap {13mm skt}
 * rear guard {13mm skt,short flat SD}
 * bumper {15mm deep skt,14mm skt,17mm skt,short ext}
 * muffler ext pipe {long FSD}[clamp]
 * check sump plate plug and screws {10mm skt, SP skt}
 * replace oil