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[matt]

 Thanks Jay,

I did undo the linkage as Shawn suggested, so that is ok.
Trying to get it to height level is the issue, between interference with the tops of the heat exchangers and the oil tube, Ted and I in our 9 hour ordeal could not get it level.



I have the engine on a board, on a floor jack. The board is pretty big, covering most of the engine base. On the thesamba I read people have used both, some  just a floor jack ( no board), some with an ATV lift as you mentioned. I bought such a lift, but returned it.  again, I just can't get the engine level because of interference.


At 2 different times once with Ted, once with Katie were able to get the lower studs in, but that was it.  Could not get the engine any higher to make level.


Jack called and suggested to re-align the clutch plate as it being slightly off can be troublesome.  I did check it with one of those plastic alignment tools with the splines, and it was hard to get in one way, but if I  pulled the plastic tool out and turned it a bit it would then  go in easy.  So none-the less Katie and I pulled the engine out. First though we had to bolt the tranny up, as the bus had to be jacked up to get the engine out.


So with the engine lowered complety, and it being rock solid stationary on the board, Katie insisted on being the one to bolt the tranny back in. ( and I it is safe, I made sure)


The board is ~ 1 inch thick large plywood plank. No one is under the car when the engine is being put in ( except maybe me to look at things.  I am very careful to keep her safe, she is a precious treasure to me.


















Yes, here in this pic you can see a flywheel lock, I tried to loosen up the plate bolts to align the plate with the engine in the compartment area, but was too much of a prob due to space, and realized  no way I could get a torque wrench on some  bolts later .  So decided to pull the engine out from under the bus.  Here the engine has been let down all the way  & solid, before Katie got under to put the trans bolts back in














 Instead of the plastic alignment tool, this time I wanted to use my metal alignment tool, - This tool though does not have splines
  -  I used many times for bugs, and never had a prob. 




























We finished the above about 9:30 pm, and she wanted to continue to put  the engine back under & try to get it in. I called it quits, having to get to work in the morning.  She has time Friday, so the plan is from Friday  ~ 3:30 till whenever.


Thanks so much Jay for your comments, always appreciated!!

[matt]

  Also just to mention, the board is bolted to the jack with a very large bolt; so the board cant  move / slip at all

[6T5 square]

you got a great kid there, Mr. Matt

[Baha (Shawn)]

 

My concern is the alignment tool. It doesn?t need to have splines. I have a 35 year old, store bought tool that is made from wood. But, it must go into the pilot bushing and be rigid when it?s in. The slightest movement and you?ll encounter the problems you?re seeing. The plastic tools that come in the clutch kits work well.

Tip for the new bus owner: your beetle stands do not work for a bus. Time for HF 6 ton stands with 24 in. of lift (or bigger)

[matt]

 Thanks John, I do & she is. Although she is more of a slave driver to get the engine in than I thought. 

Shawn, thanks,  - the alignment tool is absolutely in the pilot bushing, that was paid very strict attention to, and is tight; no moving around at all.  during install I have not yet come close with the trans drive shaft to begin to go into the clutch plate, last time the  drive shaft was high.  I will raise the bus up a bit, drop the trans again and see if that helps with giving me some room. Today/tonight should be working on it, and if not in, Ted said woefully, he will come over Sat to help.

Check on the stands. That little stand was just to help balance the engine earlier when it was pulled out from under the bus during pressure plate install.  I have bigger stands.. appreciate the double check & good eye.  Will  go  & see the HF ones you mentioned.  Most beefed stands I have are for trucks, use them when i work on my wife's (then) and Katie's jeep. The front of those things are real heavy

   thanks for any good pointers!

[kvbug (karen)]

She's a beauty.  What did Katie name her new bus???   

[matt]

 Well, ................  His name is Mr. Winslow,













                   Katie calls him Gus.

[matt]

  Well, I can't express how frustrating it has been to spend over 12 hours to get the engine in Mr. Winslow.(  This has been working with Ted and Katie...)
He has been sitting in my garage for a month, as I did odds and ends to him, but the engine install for me was the killer.



The problems with the engine install began to eat at me, beingon my mind most of the day every day, and keeping me up at night...





                 





 OK, I should have called the club earlier, but I thought I could do it, I've done bug engines many times.. so how can this be different... it is.  I know everyone lives far, so I tried to do the engine myself.

  Nope, - so I put up the white flag      for the big guns to come to help. Unfortunately, Friday,  I missed an opportunity for Shawn, Jay and Jack to come over, as I had to work.  (Like missing the lottery by a fraction)      However, Sat, Jack told me he and Jay were coming over to do the work   I called Ted for extra help.  All made it to my house very early in the morning.









I tell you, if you ever see this....



 


 It may be a tornado, but it also could be Jay doing work on your vehicle!  Man, that guy plows through the work!  Amazing to watch him!!  Engine was put under the bus, installed and bolted in, in no time!  I was absolutely shocked.   astounding!  Ted and I were like...



        What just happened??!






Of course, Jack oversaw everything, surprisingly he came without a bull horn.  Great to see him again.!





 As they left, I texted Katie (She was working as she should be) to let her know. She told me she wanted to help finish everything  , so we will be doing that this week. 


   Thank you so much Jay for the amazing, quick work!, I am honored! I learned a lot from you in the short amount of time you were here. Thanks for Jack for getting people lined up, and again Thanks Shawn tolerating all my questions for the earlier advice in doing the work.

Once again this club shows how much it really comes through for people.... I can't express how much I appreciate the help.

Now I can - and will soon be   

And I should thank Ted bigtime, although 9 straight hours of  hard work to get the engine in, with a fail  .... still learned a lot - what not to do.  All I can say is Heat Exchanger Tops!  Thanks Ted!!!

[kvbug (karen)]

Great news!  SJVWC to the rescue!                   What a labor of love..

Soon you'll be able to start enjoying it and going camping!   Oh, and is highly overrated....     

[matt]

 

  Been thinking about it.....I have a few things in mind...

[kvbug (karen)]

Jay indeed is a master.  I'm quite sure that he and Matt worked something out between themselves..

[lovebus (jack)]

J never said as thing about being paid he's just a nice guy that likes to help

[steveo]

J never said as thing about being paid he's just a nice guy that likes to help

Yeah...How does CELLY know that MATT didn't have anything in the works for a THANK YOU???

[matt]

 Ok, here is the update...


Tag-teaming heater tubes, exchangers, clutch cable



And finishing up hookups












The positive terminal on the battery was the last thing connected






OK, pushed it out of the garage, and started it up.

Ran rough for a while, seemed to smooth out, but not as good as it should be.
At the time, did not see any unconnected hoses.
Took if for a drive down the road, clutch was not adjusted well, very near floor could barely shift.
When I got out of gear, heard metallic sound, when pushed in clutch, went away.   

Coming back home, battery and EGR light came on.


Let engine cool down, got under and adjusted clutch cable as far as can go, by finger push, made a diff.

Looked in the engine compartment and found a small hose not connected.

I am not sure if it goes to this ( whatever it is)



and maybe here...





seems like there are 2 hoses going here (besides the one on the top)




One of these hoses goes to the fuel regulator, on the bottom right of the engine compartment.... this may be the issue with the poor idle.




BATTERY CHARGE LIGHT
I checked all of the lines to the voltage regulator and they tested fine. All I did to the alternator was to remove the belt via the one hex bolt under the little cover, and then put it back on. It did take a lot of prying to move the alternator even with the one hex bolt loose.  The other bolt where some manuals say to loosen ( sort of like at 5 o'clock) looks like the top of a stove bolt  - there is nothing to grab. I am not sure if some wires around the alternator were damaged when I R&R the belt (?!)  I did not yet verify by voltage if I am really getting a higher voltage at the battery when the car is running vs not.



And something very strange here... this is wired in, seems like factory.  I am not sure if the switch was ever moved during the R&R of the engine, and if it should be on hi or low. This is located above the hookup of the computer.








So this is where I am, but now have to cook for the picnic tomorrow...










Brought it home

[matt]

Seems like the switch is an altitude switch? should be on low, believing it has any impact.