VW Super Beetle Engine Removal:

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Step-by-Step Guide to Pulling a VW Engine

Introduction:

Today, we're diving into the core of the matter, quite literally, by pulling out the engine to diagnose why it refuses to turn over. While we suspect an unwelcome intruder in the intake, our task is to uncover the truth and ensure our beloved Super Beetle gets back on the road.

Tools Needed:

-8mm Wrench
-17mm Wrench
-3/8" Drive Ratchet
-1/2" Drive Ratchet
-3" Extensions
-6" Extensions
-17mm Sockets
-Vice Grips
-Wheel Chocks
-Flat Head Screwdriver
-Philips Screwdriver
-Jack
-Jack Stands

Step 1 - Preliminary Checks

Our first mission is to rule out a snapped crankshaft, a rare but serious issue. Considering the limited end play on the crank, it's unlikely, but we need to be certain. To unravel the mystery, we're set to pull the engine and dismantle it for a closer inspection.

Step 2 - Preparing for Extraction

With no battery in the car, we kick off the process with the deck lid open. The vacuum hoses from the carburetor are disconnected, and the air cleaner is removed. For those less familiar with Volkswagen engine wiring, a crucial step is labeling every wire to ensure a seamless reconnection later. The wiring at the generator, along with connections to the coil and oil pressure switch, is detached.

Step 3 - Detaching Components

The accelerator cable bids farewell to the carburetor, nestled back into the fan shroud. Although the reverse light harness wasn't connected, it's pulled away from the coil. Heater hose clamps are loosened, and the hoses are set free.

Step 4 - Removing Engine Components

The left and right pre-heater pipe tins are removed, allowing access to the rear engine tin. Spark plug wires are strategically pulled in to prevent pinching during engine removal. For those cautious, pulling out the spark plug wires entirely is a viable option.

Step 5 - Jacking and Loosening

A potential hurdle surfaces with a stubborn upper right engine nut behind the fan shroud. To tackle this, we secure the front wheels, jack up the rear, and place it on jack stands beneath the torsion housing.

Step 6 - Underneath the Engine

Underneath, heater box cables bid farewell to the heater boxes, and the hoses to the car are disconnected. The accelerator cable is pulled clear, and the fuel line is disconnected from the steel fuel line at the rear engine tin.

Step 7 - Engine Extraction

Lower engine nuts at the transmission bottom are unthreaded, and the tricky D-bolt on the starter is managed with vice grips. Another pair of hands assists in loosening the upper right engine nut. With the engine nuts and bolts freed, the engine is ready for extraction.

Step 8 - Balancing Act

A jack is positioned under the engine sump plate, lifting the engine slightly and pulling it back from the transmission. The delicate dance of pulling, dropping, and pulling back continues until the engine is clear of the apron, and the lower engine studs are free from the transmission.

Step 9 - Engine on the Move

With precision, the engine is dropped into a rolling engine dolly. The jack is then repositioned beneath the chassis, lifting the back of the car until the engine can be rolled out.

Final Steps and What's Next

As the jack stands are removed, the car is lowered, and the engine is prepped for degreasing and cleaning. Stay tuned for our upcoming video, where we'll dive into the disassembly process. Meanwhile, for all your vintage Volkswagen parts and accessories, head over to JBugs.com. Let's bring that Super Beetle back to life!

Video Transcript:

Intro Hi, Sam here with JBugs.com Today, our 1971 Super Beetle restoration begins by pulling the engine to find out why it won't turn over. We’re guessing that something dropped into the intake and found its way into a cylinder. Hopefully it isn’t a snapped crankshaft, but that is unlikely as there isn’t much end play on the crank. Either way, to find out why, we have to pull the engine out and get it taken apart. Vehicle Preparation There isn't a battery in our car to disconnect, so we start with our decklid open and disconnect the vacuum hoses from our carburetor and remove the air cleaner. Next, if you aren't familiar with Volkswagen engine wiring, label every wire so you know where to hook it back up later. The wiring at the generator is removed and the harness is pulled up away from the engine along with the wire from the coil and the oil pressure switch. The accelerator cable is disconnected from the carburetor and the cable is pushed back into the fan shroud. The reverse light harness wasn't hooked up, it would have gone to the coil, but it was still in place near the coil so it was pulled up and away from the engine. The clamps for the heater hoses, at the fan shroud, are loosened and the hoses are removed. Engine Component Disassembly The left and right pre-heater pipe tins are removed so the rear engine tin can be removed. The spark plug wires are pulled in from the edge of the engine to make sure they won't be pinched when the engine is dropped. You could also simply pull out the spark plug wires as well to ensure that. The upper right engine nut, behind the fan shroud, is loosened but our nut wouldn't come loose as the starter bolt kept spinning. Engine Bolt Removal So we chalk the front wheels and jacked up the rear end of the car, set it on jack stands placed under the torsion housing. Undercarriage Component Removal Underneath the engine, the heater box cables are disconnected from the heater boxes and the heater hoses to the car are disconnected from the heater boxes. The accelerator cable is pulled clear of the back of the engine and the fuel line is disconnected from the steel fuel line at the rear engine tin. There isn't any fuel in our car so we don't need to worry about the fuel leaking but have a plug ready for your line if there is fuel in your system. Next, the lower two engine nuts at the bottom of the transmission are un-threaded from the engine and the troublesome D-bolt on the starter is held with a pair of vice grips, while another person loosens the upper right engine nut from behind the fan shroud. The upper right engine bolt was then loosened and removed from the engine and our engine can now be pulled out and dropped. Engine Removal A jack is positioned underneath the engine sump plate and the engine is jacked up slightly and pulled back a bit from the transmission. Removing the engine is a balancing act of pulling the engine back a little and dropping the engine a little and then pulling it back until it is clear of the apron and the lower engine studs are clear of the transmission. With the engine finally backed out of the transmission far enough, the engine is dropped down and into a rolling engine dolly. Then, the jack was re-positioned underneath the middle of the chassis of the car and the back of the car is jacked up until the engine can be rolled out from underneath the car. The jack stands can be removed and the car can be lowered back down to the ground and with the engine out it will be degreased and cleaned, then we'll get the engine mounted to an engine stand and start the disassembly. That process will be covered in an upcoming video. In the mean time, head over to JBugs.com for all your vintage Volkswagen parts and accessories.