'95 LWB 150 minibus conversion

[Luke]

ok pas pump - the 3x 13mm bolts on the pulley undo them then the long bolt you'l then be able to see..... undo that - the pump will come away leaving the bracket - you can leave the bracket on but dont throw it incase the new engine is non pas) just tie the pump up to the side of the engine bay so it's not straining the pipes and wont get damaged

[Luke]

manifold - personally i'd try to split it at the joint onto the down pipe - if it splits there ok

if not the pipe from the manifold up to the intake is the egr - unbolt it all then take the full manifiold off the engine - you could then split the exhaust at a joint further down and get the whole lot out of the way - depending on what exhaust you have

[Nadjenka]

ok pas pump - the 3x 13mm bolts on the pulley undo them then the long bolt you'l then be able to see..... undo that - the pump will come away leaving the bracket - you can leave the bracket on but dont throw it incase the new engine is non pas) just tie the pump up to the side of the engine bay so it's not straining the pipes and wont get damaged

By that you mean those three bolts I see at the front? Basically to take the wheel off (is that the "pulley"?)

[Luke]

yeah thats it - i was just trying to be helpfull so you'd get the right spanner

once its off you'lll see the long bolt - same spanner (well 2 of them) undo it

[Nadjenka]

yeah thats it - i was just trying to be helpfull so you'd get the right spanner

once its off you'lll see the long bolt - same spanner (well 2 of them) undo it

Thanks, gonna try it

As for the starter - Fastmower - it has worked and it's now unplugged Thanks.

[Nadjenka]

Right, those three bolts did not release the wheel (pulley?) I'm not going to try to force it out, but I have found the "long bolt" at the rear of the pump. Unbolted it there and it has moved to the side slightly, thanks Still not enough to get the torx socket in to undo the torx screws holding it onto the engine, but - it might be just luck of puff now...

I'm lost now, Haynes says I should remove the fuel pump now, but there is just so many bolts and so little pictures... Had to move onto that in attempt to remove the manifold from the engine itself as one of the bolts in the middle of the manifold refuses to go out properly and I don't want to snap it, so... fuel pump it is

Got the belt off it, got the wheel off (pulley? or "sprocket" as described under its picture in Haynes), I disconnected the EGR throttle valve control rod but can't get to the support bracket bolts. Again - it feels like I missed something there too Oh, what if I just used the angle grinder???

[fastmower]

Give the pas pulley a bit of a tap with a hammer Nadjenka - it's probably just rust holding it on.

I've never removed an injector pump so can't help there I'm afraid, but I remember that getting the manifold bolts all undone can be a fairly big pain in the ass! It's generally just a case of keeping at it - sometimes you can oly get a tiny bit of a turn on a bolt and then have to turn the spanner around to get another tiny bit of a turn etc.

Sometimes it's best to just keep taking bits off one at a time until you get where you want to be - don't take Haynes as gospel - if you see a bit that you think is in the way then just remove it and try and remember where it came from!

Andy

[Nadjenka]

I remember that getting the manifold bolts all undone can be a fairly big pain in the ass! It's generally just a case of keeping at it - sometimes you can oly get a tiny bit of a turn on a bolt and then have to turn the spanner around to get another tiny bit of a turn etc.

That's soooo true! But I wouldn't mind that. Problem is that the rear bolt in the middle manifold joint is coming out under an angle - which means if I try to force it out that way (even doing milimetres at a time) it would either destroy the thread or snap the bolt - which I don't want. Therefore I'm looking to remove the fuel pump - which proves to be another pain due to lack of access and way too many pipes for my liking.

So another question pops to mind - do I REALLY need to take the manifold off? Haynes recommends it purely to create "more room" for the engine to swing out. Is that really what I need to do then? Has anybody tried it with the manifold still on? Banana manifold, but I'm sure you can see that on the pictures...

[jnwferguson]

Just disconnect the fuel lines unbolt the gearbox and any cables pipes you can see then pull the engine out complete thats the way I did my mk4 once you get it out then you can strip everything off also makes it easier to fit cam belt etc.
cheers jim.

[Nadjenka]

Again - I chose human approach and talked nicely to the manifold bolts Offered some WD40 and couple of swear words and here it is - the reason for my grief



Don't know where to start on those fuel lines, but I have called the man of the day in again, because I'm sure I'd screw up that fuel pump and I don't want that. Removed half of the manifold, and back to the other side of the engine. I removed wiring from that blue pin, anybody knows what that is? I'm labelling all the wires as I remove them because I wouldn't know which one belongs where when the new engine goes in Drivers side of the engine. Can't find a picture of it anywhere, what is this?

[Luke]

thats the oil pressure switch

[Luke]

you dont need the fuel pump off - leave it on

have you got the pas pulley off yet as fastmower says tap it off - 180deg tap then 180 again tap repeat untill off

[Nadjenka]

thats the oil pressure switch

Thanks Luke. It had earth bolted just next to it, right?

[Nadjenka]

you dont need the fuel pump off - leave it on

have you got the pas pulley off yet as fastmower says tap it off - 180deg tap then 180 again tap repeat untill off

No I didn't. As I wrote before - I found that long bolt you were referring to and released it from the other side (not from behind the pulley, but from the rear of the mount) and I can now slide the pump to the side. It's still in a way of one of the three torx bolts mounting it onto the engine though...

[Nadjenka]

Oh - and the pump problem - I'm taking it off only because Haynes says I need to take off the banana manifold before I take the engine out to create more room for the engine to slide out. Of course this is not possible unless I remove the fuel pump first. Not sure if Haynes is just trying to get on my nerves or keep me busy undoing bolt after bolt, or what... Anyway - it's good learning excercise I suppose.