Dismantling a 71 vw 1200 engine Part 2

Back in april... after getting the manifold nut removed i proceeded to soak the bolts which are holding the silencer onto the exhaust manifold... i will need to remove the silencer box so that the whole exhaust and heater box assembly can be removed.....

Before i go into the details... im sure you wld have noticed that the title has 71 written on it instead of 65 ... well i knew that the engine had been changed in my car by the former owners but i never bothered to check the age of my engine.... after checking the Vin number i found it to be an engine made in 1971.... and looking at the number of Brazilian parts on the engine... im guessing it was poorly overhauled.... well maybe not poorly overhauled but definitely not a top overhaul anyway back to dismantling

After soaking it for a week it still did not get loose... i kept soaking it and hitting it with a chisel and hammer hoping it will loosen up ...but nothing... i tried to get a closer look... and found what seem like both the male and female connections had fused together with rust.... then i thought hmmm i might else well put a new Scat system or something like that... basically a new exhaust assembly..... i wanted to keep the heater boxes so used my angle grinder to cut the very tip of the silencer off... as shown below..... as soon ass both sides were cut, .... the whole assembly the came apart easily....

Below is the exhaust assembly.....

Engine looking a little smaller.........

After looking over the engine for no apparent reason.... taking shots in between as i did..... i found a bolt which was missing a nut... its something which is connected with the distributor.... hmmmm i wonder if i had driven 5 years without it........ or did it go missing when my mechanic replaced the contact points and serviced the distributor..... back in 2003??

BUGgers do Cyberjaya

Woah... the BUGgers club or now known as Volksriders of Malaysia is picking up well.... and our forum is getting more and more lively by the day with over 150 members to date... so if you know anyone who has a classic volkswagen be it a Beetle, Ghia, Kombi, Rabbit, Thing or has a passion on them, get them to join us to learn and share knowledge on the 'Peoples Wagen'.. On behalve of our founder Shawn, i wld like to welcome you to our forum Volksriders

Below is a slide of our 5th G2G held in Cyberjaya last month....

BUGgers go to PD

A couple of weeks ago a bunch of BUGgers took a day drive to Port Dickson, Negeri Sembilan, Malaysia. We took the old roads through Nilai and Seremban and safely arrived at 10th mile Blue Lagoon, P.D.

It was a pleasant drive there eventhough it rained heavily on the way to Nilai at the start of the journey. I met the guys in Nilai as they stopped for breakfast. Left my car (Satria) there and joined Shawn in his bug as we continued on our journey.

heres a 'few' pixx

4th BUGger's G2G

The BUGgers had a little get together down in Klang end of last month..... 17 bugs turned up... even a fiat 500 turned up.... well it does have its engine in the rear.....

Dismantling a 65 vw 1200 engine Part 1

So i was bored and fiddling around the house and thought hey i think i shall start dismantling my vw engine..... yup just another one of my my wild idea.... so off i went about taking out my tools and dusting off John Muir book 'How to keep you vw Alive'..........

well first thing you need is a 36mm socket..... damn.... i dont have one... so off i went to the hardware shop to buy one......i figured i need to go to big fancy shop to find it but nope... after i went to a few but no luck... the biggest they have is 32mm... i even went to Ace but they didnt have them either.... i finally went to the shop near my house which isnt that fancy....and guess what.... they have a few types!!! but i also need to get a bigger ratchet... :(

ok now to start... Get the 36mm socket onto the that big nut on the fan and a with another hand, get a big/medium screw driver wedged into the slot on the Alternator/Generator to stop it from turning..... once your in position pull on the ratchet to loosen the big nut on the fan... only loosen the nut yah... dont remove it....... as you can see i used a feet on the fan cover for leverage... it was a little tricky trying to keep the generator from moving.......



Ok next, the generator needs to come off.... there is a strap that goes around the generator which you will need to loosen of and get it out of the way... dont bend it too much yah... remove all the bolts on either side of the fan shroud and just pull the whole assembley up and off the engine.. watch the cooling tower which is in side the fan shroud......


I then removed the carburetor which was pretty straight forward.....


Next i removed the cooling tower. It has one nut on the top of the base and two which are under the base.. you will need to remove the left side engine tin to get to this two nuts....I just went and removed all the engine tin........ Once removed, plug the two holes with a piece of cloth .... yeah i know i dont need to do that since i going to try and dismantle the whole engine but... my engine is pretty dirty with not only grease and oil but alot of loose dirt and dust, paint chips etc etc....


Ok now back to the generator and fan assembly.... Place the shroud on its back with the generator facing up.... Unscrew the four bolts around the fan cover and you will be able to pull the generator and fan out of the fan shroud..........

tada!!!!!! its out......

Ok... now we remove the really big nut we loosened at the very first step earlier..... The fan can be removed now which will expose two more nuts which will remove the fan cover from the generator.


Then i wanted to remove the mufflers..... the one on the right came off after some tugging. You will need to remove the clamps on either side lah.... but the left side muffler didnt budge...... some WD40 here and there and it still didnt move..... somemore WD40 and left over night and it till didnot give up..... well... im not going to give up either.....


After some thinking... i decided to tighten a hose clamp on the muffler then using a hammer i tamped on the tightening screw of the hose clamp while pulling the muffler with my free hand..... it worked!!!!!! but goosh was it tight.... i had to reposition the clamp three time before the muffler came loose........




The intake manifold was easy to remove...... all you need to do is remove all four bolts; 2 on each port and 2 one each exhaust..... Then i set out to remove the exhaust which was as simple as the manifold but.... one of the nuts was rusted solid...... tried my best but landed up rounding off the nut.... so i sprayed it with WD40 and tried chipping on it hoping it would turn....... nope ... nothing happened.... so i leave it to soak in WD40 and left it for a week.........

A week later and it still was not budging so ........ out came the hammer and chisel and saw...... the nut was in such a position that i could not reach with any kind of power tool..... sigh..... the finally aafter 2 hours of banging on it with a chisel and sawing the nut....... it came loose/...... but yes ... i damaged the stud... sigh!.........

As you can seen below, theres not much room for me to move about......... but i dont want to risk leaving the engine outside at the back of the house....... not enough someone has stolen my man hole cover.... dont want anyone making of with my engine......


Engine tin after some scrubbing and cleaning.......



End of PART 1

BUGgers & AMC club's Drive to Bagan Lalang

Did you know that there is a stretch of coast at Bagan Lalang which is now called Goldcoast????... sheesh!!! how original wan......

Anyway a bunch of us vw beetle owners and a few other classic car owners took a drive to Bagan Lalang last Sunday.... oh wait do you guys even know where Bagan Lalang is? :) well if you dont its a coastal area just after Sepang Town.... Dont know where Sepang is? ... You know F1 Sepang Circuit ... aaa thats right! its some what a whiles way from there...

It was such a hot day... but of cos it rained like nobodies business later in the evening... luckily i was already back home by then....

i visited Bagan Lalang almost a decade ago.... and boy has it changed.... it used to be a nice quiet place .... the beach wasnt that great but wide...and the water was not too nice either.... but it was a great place for a picnic...... there was a restaurant there which was famous for its 'Ikan Bakar' (Grilled Fish) and the sea food wasnt have bad either....

So yeah ... now ...almost ten years later.... they are calling it Goldcoast.... and they are building a stretch of water villas on stilts... there goes the neighbourhood lah.... the place was packed with visitors .... the roads are alot better but its jammed with cars... maybe because it was a sunday...... there are alot of new stalls along the stretch.... but the food really sucked!... .... .... sigh!!! it was sad lah... i really hope this place is not ruined further by stupid humans who only know how to leave rubbish wherever they go......

Well anyway.... the drive was ok besides some miscommunication, route problems, car problems, etc etc but hey... thats what you get when you bring more then 5 people/cars together right...

more then 10 beetles showed up and about half a dozen classics of other makes from the AMC club joined us..... have a look at the slide show below.... i felt the gathering was pretty good .... maybe the next time will be better if we can iron out some issues.....

BUGgers meet 14Mar08

A bunch of us gathered at Padang Utara in PJ.....

VW Air Cool Powered Proton Satria

Ok i lied.... its just my beetle engine in the boot of my Proton satria..... luckily its only a 1200cc engine which was small enough to fit in there....

Didnt want to leave the engine at the paint shop since im not sure how long its going to be there... you never know what might go missing.......

much to my wife's disapproval... its now in the store room next to the fridge.... :P


mo

How Not To Remove Your Beetle Engine.

So.... i decided to remove the engine..... weeks of telling myself i will have to read the chapters on Engine Removel fell on deaf ears.... Chinese New Year was coming up soon ...so i needed to remove the engine soon bcos the shop will be closed for the holidays ...

I cldnt wait for my friend to be free... and since i have too much time on my side.... hmmm so i get to the shop with all my tools, two jack stands and a small 2 ton hydraulic jack and i get myself cracking.... There were a few more things i wanted to remove from the car, like the Hood Latch and the Wiper and Break Fluid reservoir.




Both reservoirs removed.......



I started labeling all the wiring on the engine before removing all of the connections..... but then i got a little side tracked and started removing the engine lid latch. The thing was pretty much covered in years of paint... had to be scrap it all off before the screws could even budge......




While i was on that ..... i thought hey i better remove the engine cover too..... unbolt the nuts and release the spring in the middle.... and it was off....


Some engine parts come off like the air strainer..................

U will need to remove this engine tin cover for clearance.

A close up of the spring clip of the engine lid cover....... next we (By that i mean me, myself and I) raise the car on jackstands.... but since i only have a small hydraulic jack.... the back tyres werent event off the ground....... (Pls make sure you have or borrow a BIG hyraulic jack) the car needs to be really really off the ground...... Ok now place the HJ under the engine to support it........

The next thing you should not do is to be under your car which is on jackstands... and start taking pictures of spiders...... ok after a few shots.... i start looking for the bolts and nuts which are holding the engine together.... believe it or not ...there is only 4 bolts holding the whole thing together..........

Above you can see the top two bolts which i found to be the hardest to remove...... oh yeah did i mention that you will need a 17mm bent box-end wrenches for all except one (the one attached to the starter motor).. which incidentally i didnt have .... luckily the paintshop guy had one....

Its pretty slimy and grease under there.... so it was a little hard finding the bottom two bolts...especially when you dont know what you're looking for.... oh by the way remove the bottom two first before you loosen the top two....... and the bolts which is holding part of the starter motor will need another hand to help loosen it.... doing it alone took me nearly half-an-hour for that one nut alone......

While i was taking a breather i decide to take a look around the engine to see if i missed out on any wires or connections which are still attached to the engine........ thats when i found that the accelerator cable was still attached to the trottle..... detached that yah.....

below is a view of the back of the fan shroud/cover...... you can see where the two top bolts are attached too...... and where the trottle cable enters from...

Ok so now that i have everything off..... i start to yank on the engine..... heee hoooo heeee hoooo...... it comes of about 2 inches then it just stops... "clunck"..... after that its just wont come off....... i was tired and try if i may it just didnt budge ...... so thats when i grew a brain and called my uncle.... (remember him )

Now i dont know why i did what i did next .....but i did it ok.... just dont ask me why.... while the engine is hanging half way like that.... i start draining the engine oil........ i leave it to drain and the take the oil sump cover with me (like i said....dont ask why) ... and then i go pick my uncle up.......

He has a big ass hydraulic jack which cant fit in my car so we take his car.... and when we reach the paint shop he gets behind the beetle to check things out while i get the jack out of his car... before i can even do anything...."boom" he has the engine loose..... but because i didnt have the car jacked high enough ...the engine is just stuck.....

We then jack the car higher and then replace the small jack under the engine with the bigger one and "boom" he has the engine resting on the jack......... but while trying to get the engine off the jack and on to the floor it seems to be stuck..... the egde of the jack is stuck in the sump which i left open.... and forgot to cover back up.... and further more i had left the cover back at my car.....which was back at my uncle's place.... sigh.... in the end the oil strainer had jammed itself between the HJ's teeth.... we get the engine finally off the jack but not without tearing the oil strainer off of the sump........ one more item to add to my long list of parts........... sigh........

Where the engine used to be..........

Where the engine is residing now..........

The torn oil strainer......... :(

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end of how you should not remove your vw beetle engine.........

.....mo

TitBits Removel

Ah... its been awhile izzinit.... well ...as of the begining of January..... the car is pretty much stripped of its paint and bondo and crap... the roof is in better shape that i thought it was.... actually its in better shape then rest of the car... the front passenger side fender is pretty busted up and was not fixed well by who ever the former owners sent it too...

A couple of dents have showed up... not surprisingly lah.... filled-in with so much plaster... hmmm ... anyway all these dents must me dealt with before any prep work can be done...

To do a proper paint job i wanted to make sure that all parts small and big to be removed from the shell..... so since the paint shop does not have enought workers to work on my car... i decided to help remove some of these 'titbits'

The window glass regulator is held on by these 10mm bolts. Remove all these bolts and the regulator should come off easily.... yeah right... it took a great deal of pulling and pushing to remove it. Luckily i managed to remove it without breaking anything ...most importantly the glass was intact.....

To remove the quarter glass, first remove the 10mm bolt holding the metal bracket in the middle... then bend the bracket gently away from the glass as seen above, then look up into the channel as seen below..... you will see a phillips head screw. Remove it and wiggle the quarter glass assembly out whole.... try to be gentle yeah...

Remove the clips gently which holds the window glass rubber and brush thingy (sorry dont know the name). since im painting the car i didnt have to care about scretching the paint.... but be very carefull if your only changing this part with nice paint on your car....

To remove the hand latch your will need to remove the door rubber weather strip near the door catch... Remove the screw and wiggle the handle a little bit to get it loose... use a mallet if nessesary...

Parts slowly pilling up......

The drivers window rubber was of a newer type which was glued on, so it was easier to remove....... while the passeger side was of a rubber fused in metal brace of some kind which was rusted and rotten.... a lot of bending and yanking and it came off....

The window chrome trim on the passenger side was the only one that had proper clips securing it.....

Removing the glove box cover was a breezze...

Removing the headlight, wiper and starter switches where a little harder to do without the proper tools.... Try and find or make the appropreate tools if you dont want to risk damaging these parts........

Twist these metal studs behind the dash to remove the dashboard grill... be gentle yeah....

How do you install a fan into your VW beetle.......? Just jam a few screws into the bottom of the dash and there you have it............. aaaaaaaaarrrrrrrrrrrggghhhhhh!!!!

Removed all the electrical bits...... left over wire... and wires that lead to nothing.... nothing?

Can anyone tell me what this switch below the dash next to the steering rod is for?

Removed the interior light door switch..... checkout the crusted rubber

The paint shop guy removed all the glass for me ... but as seen below .... i removed all the headliner and scuff and other sticky stuff on the interior....

The headliner removed.........

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..... had decided to remove the engine .... so without any experience or help i sent out to remove the 1200cc engine from my beetle....... so look out for my next post... as we see... What you should not do when removing a 1965 vw beetle engine.........