series 2a 88 engine refitting

i have fitted new shells,pistons and rings in my old girl,when refitting the engiine using a decent hoist is it ok to fit the dizzy/fuelpump/starter etc pre fitting,i stripped them all off prior to removal as i did it by myself from a beam off the roofrack using a block and tackle so weight was important, the cylinder head was already off to investigate the probs i was having (pressurised crankcase)which are sorted now so its all back together apart from the ancillaries i have mentioned and as soon as it stops raining its going back in,i just dont want to be underneath in the mud any more than necessary if i can help it hence my post,advice appreciated
thanks
ryn@wetwarmwindygreywestcornwall

Have you used an alignment tool or old first motion shaft to fit the clutch ? If all is correct they are doable on your own but easier with help.

thanks for the reply,the clutch is still on,i didnt do the mains,just down to the bigends

A couple of long studs in flywheel housing helps with alignment, when I did mine ended up buying a hoist leveller made it lot easier

hi,a pal has lent me his crane/hoist and as it happens i bought one of those levellers from machine mart as a thankyou to him for the lend,i have never done this before and when i took the lump out it was a struggle hence i dont want to put all the ancilleries on and get it jammed or break anything

I would leave the fuel pump off, the glass bowl might get knocked on the way in. Especially If you don't have another pair of eyes watching the things you're not.

Co!

Unless you’re a magician It’s a bigger struggle getting it back in , I tried to ensure the gap between engine and gearbox was even all around , if it’s stuck about 1-2 inches out it’s prob the gearbox shaft not aligned with clutch so may need to turn crank a bit

thanks for the advice lads,i think that i will put the starter on and leave the rest til its in,it was the fuel pump and dizzy which i didnt want to damage so best to safe and sure,
atb
ryn

got it in today and am a bit worried,the starting handle is a bit off to the left,about 2inches looking at the vehicle from the front where it goes through the chassis hole,i noticed this when turning it to get the engine output shaft into the g/box,
i would have thought it would be dead centre,the new engine mounts seem to be fitted o.k.
any cause for alarm?,

Was it central before you took it out?

Col

i dont know,i have never had cause to use the handle 'til yesterday ,i only noticed when used to turn the crankshaft and engage the splines

When you pass the starter handle through the bumper and into the crank nut is the handle sticking out straight or at an angle?

Col

thanks for your post,i have just checked and it is about a mil off square between the back of the bumper edge and engaged starter handle shaft so all good,
atb,
Ryn

Have you got it the correct engine mount holes , I can’t remember which is the right pair though

i think its sorted now,
thanks for your reply,it is appreciated
atb,
Ryn

rynner said:

got it in today and am a bit worried,the starting handle is a bit off to the left,about 2inches looking at the vehicle from the front where it goes through the chassis hole,i noticed this when turning it to get the engine output shaft into the g/box,
i would have thought it would be dead centre,the new engine mounts seem to be fitted o.k.
any cause for alarm?,

Click to expand...

all o.k

Glad you sorted it, was there a problem stopping it aligning properly

all done a while ago, no probs but the starting handle being off centre threw me at the time,ive done a few hundred trouble free miles now.
the advice,pics and answers i received helped a great deal when fitting my engine, there is another thread going atm with similar probs so hence my 'bumping' the thread.
atb

Well I can’t get mine back in

centred the clutch ok. Won’t go that last inch and a half. I’ve rocked it, shoved it, kicked it and levered it. All with shunting the crank round.
It’s ard on mi tod

I’ve got a lift above it, a trolly Jack below it. The gearbox is floating and I’m sick of cutting up wedges to adjust attack angles and heights.

try again tomorrow.

Bobsticle said:

Well I can’t get mine back in

centred the clutch ok. Won’t go that last inch and a half. I’ve rocked it, shoved it, kicked it and levered it. All with shunting the crank round.
It’s ard on mi tod

I’ve got a lift above it, a trolly Jack below it. The gearbox is floating and I’m sick of cutting up wedges to adjust attack angles and heights.

try again tomorrow.

Click to expand...

I think last time I had my tdi out I had to wind the engine in the last inch or so with a couple of nuts, and the only thing that can make that hard is the spigot bush.
Iirc the s2 was also a toss, I vaguely recall no engine mounts to give me max wiggle room.