by Richard Atwell
Can you pull an engine in 30 minutes? I can't. I can drop one fairly quickly if everything is disconnected but otherwise it always takes longer than expected. I've tried using exaggeration to speed up the process but it just doesn't seem to help like it does on the internet. :-)
Some parts on the bus cannot be removed unless some other part is removed first. This tech article aims to expose those obstacles and others. I've highlighted the critical blocking items in yellow where applicable.
After you install and run your engine it's a good idea to retorque the heads but it cannot be done without removing some parts first:
I wish I had a dollar for every time somebody suggested removing a cylinder head from the engine with the engine installed in the bus. It's almost always quicker to remove the engine (although you will lose access to the underside unless you use an ATV jack or engine stand to raise the engine again).
Here's a photo of the front deflector and under cylinder tin pieces that make head removal nontrivial:
Note: you can remove the cylinder with the heat exchanger attached but I don't know why you would want to do it that way. Of course, installing the head with the heat exchanger already mounted makes sense because you can ensure the best fit between the exhaust port and manifold on the bench. Mounting the heat exchangers with the engine already in the bus is no fun because they are so heavy.
To remove the firewall on a Type 4 engine...
There are 2 shift rods grommets on the rear shift rod and 3 on later models starting part way through 1977 with VIN 217 2053 839 (unless the dealer performed the upgrade to an earlier model).
Here a photo to demonstrate how long the rear shift rod is: it is a lot longer than you might think:
Note: the frontmost rear shift rod grommet can be replaced if you disconnect the front shift rod and pull the rear shift rod out of the front of the shift rod tube but the rear (or middle and rear) grommet must be replaced after removing the shift rod from the rear opening.
You will regret attempting the following. These tasks are not impossible, just frustrating in the extreme and best done with other parts removed first:
03/05/05 - Created
09/07/11 - Fixed broken photos, added translate button, updated footer