Trying to remove KV to fit ABY

[cquattropower]

Ok guys I am trying to take my kv engine out so I can replace it with a aby lump and gearbox, but as usual I am hitting a few walls.

Firstly, how does the starter motor come out, I have removed a visable bolt at the bottom, but its not moving.

Secondly how do you take the exhaust manifold off, I have removed all the top bolts and 3 of the lower ones closest to the front of the car but its the ones at the back I cant seem to get to?

Thirdly I have removed the drivers side suspension but cannot get it away from the steering rod, there is a ball joint coming off that piece sticking out of the shock body, how do you get that off?

Fourthly the moment i put the tool into the bolt on the prop it went round, short of going mad with an angle grinder, any ideas, also how do you disconnct the front section of the prop from the rear?

And I thought getting the engine out would be easy,,,, DOH!!!!

Any help on this would be great.

Cheers guys

[baltiboyS2]

Take a look how the starter fits onto the aby block then you should get a idea of were the bolts are located on your engine 5pot block are all pretty much the same

cheers Raj

[baltiboyS2]

Undoing the prop again get screwdriver and wedge the prop on the other side and undo the allan bolt and just turn it as you need for the next one

cheers Raj

[avants2turbo]

have u ever worked on a car before mate?
Theres usually 3 bolts holding the starter motor on, the exhaust manifold will come off if u undo all the manifold nuts. The ball joint should be split with a ball joint splitting tool. As for the prop, best off using an air gun/ratchet to undo the bolts as this doesnt apply any turning motion to thd prop. To seperate the prop u want to have a look at the tips/hints section there is a writeup on overhauling the prop, but basically your looking for any caps covering where there could be a circlip holding the "pivot" pin in place, when you have the circlips out tap the pivot pin out with a drift and mallet.

Hope some of this is usefull to you,
Keith

[cquattropower]

Yes that is usefull , cheers again raj, avants2turbo , you cheeky *******, yes I have worked on many cars, but not for a couple of years. Only worked on VW's and Hondas , little jobs etc. Space is at a premium with this engine leaning over to one side. I am hoping the 20v will be easier to work on!! Wasnt sure if the ball joint was screwed into the arm coming from the shock as there is a thread there.

[re2500]

Keep at it mate, your doing the right thing by asking people on here.
As for haveing more room in the engine bay with the 20vt. You'll barely fit a rizla in there once its in! Just try to replace ANYTHING tired looking before you but the ABY in, you'll never want to take it out once youve got the engine in, trust me!
Pieces of advice on things i didnt do and now regret it, remove the bellhousing spacer and convert to 3B single mass flywheel (do a search on the forum to understand more), put in a new clutch and clutch slave cylinder.
To make your life easier getting the ABY engine into your series 2 engine bay: (i used to have a series 2 and did a couple of KV engine swaps)
I dont kow how viable it is but i wonder if you could carefully cut the slam panel section out between the headlights and make it bolt in bolt out (like the series 3's) would make getting that big turbo engine in and out a hell of alot easier.

[cquattropower]

car

Funny you should mention the front of the car, I got annoyed and went mad with the angle grinder, this should help a bit. I know that fitting the 3b flywheel makes for quicker revving as its lighter, can I use the clutch that I already have as its almost new?

[re2500]

Nope, afraid not, the aby and 3b clutches are different. I retained me ABY clutch as i looked as though it had little wear. I found when the engine was fitted and running that it was very heavy, i wish i'd changed it now.

[spink]

I must say the t85s are more awkard that the later ones.I found it easier to take the front pipe off the manifold and then take the engine out,saying that if you dont need to keep the front pipe for anything just saw through it.Starter has 2 bolts,are you sure you havn't removed a bellhousing>block bolt?as the starter will just about fall out when its bolts are taken out.another bolt to look out for is the one right at the bottom of the block,13mm i think.Sometimes they are caked in oil and mud and you can't see them and then you wonder why the engine won't separate from the box,subframe is in the way of this bolt aswell.

[20Vcqdriver]

Ok guys I am trying to take my kv engine out so I can replace it with a aby lump and gearbox, but as usual I am hitting a few walls.

Firstly, how does the starter motor come out, I have removed a visable bolt at the bottom, but its not moving.

Secondly how do you take the exhaust manifold off, I have removed all the top bolts and 3 of the lower ones closest to the front of the car but its the ones at the back I cant seem to get to?

Thirdly I have removed the drivers side suspension but cannot get it away from the steering rod, there is a ball joint coming off that piece sticking out of the shock body, how do you get that off?

Fourthly the moment i put the tool into the bolt on the prop it went round, short of going mad with an angle grinder, any ideas, also how do you disconnct the front section of the prop from the rear?

And I thought getting the engine out would be easy,,,, DOH!!!!

Any help on this would be great.

Cheers guys

1. The starter has 2 bolts. One at the top one at the bottom.
2. When I removed my KV I stripped the inlet side and left the exhaust manifold on, then removed the head with it in situ, much easier option and aids engine removal if following 2nd option below.
3. Why remove the drivers side suspension? Two ways of removing the engine in a series 2. Remove the subframe and then support the engine ,remove the engine mounts and drop it down or as I did borrow an engine crane from work removed head and anything attached between engine and rest of car, raised the front as high as poss on stands and the engine comes out at almost vertical angle. Not a job on your own if not done before.
4. Prop bolts can be a pain. I hammered in a torx bit attached to a 1/2" drive and impact driver if they would not budge or rounded off.

Good luck.

[quattrostyle]

leave the exhaust manifold as is. It's possible to get the engine out without removing the inlet manifold also and even without chopping the front end off. Only thing you need to do is remove the front pully off the crank and off you go.

I removed and placed multiple 5 cilinders out off type 85 cars without chopping or what so ever

But like 20Vcqdriver said it is easier to remove the inlet manifold before and removing it isn't very hard to do.

Maybe I shouldn't say this but how smart is it to start a project like this when you're having problems with this allready?

Well good luck.

[bluequattro]

i cut the fronts out of type 85 s when i break them to get the engines out, some i ve dropped complete with subframe
ball joints should be easy with a pry bar once bolt removed, do you mean the steering arm? free nut part way, smack the side of the strut with a hammer around the area of the arm and it should be easy take off.
as for the prop put another spanner on next bolt and turn until it hits the body then you can undo it easily

space is tighter with an aby but its worth the hassle

[cquattropower]

Thanks for that guys, the inlet manifold is off and now I will tackle the other problems, I have taken many different engines out of other cars but the cars were all a lot younger with less rusted bolts etc. The whole point of taking on this project is to restore a car that I believe to be a very good classic car and to give me a challenge, on previous engine swaps i have had challenges and the only way to overcome them was by phone calls and the trusted haynes manual and trial and error, now we have the forums and so I am going to ask questions to any problem that I have, as numerous people have encountered these problems before and I might as well pick their brains for little tips. I will suceed in this project, its just a case of when.

I think once this engine is out then I can concentrate on getting all the bits together on the aby and removing and cleaning or replacing as I go.

Hopefully engine and gearbox will come out tommorrrow.

[caterpillar]

easier way: take out the engine, tranny, AND xmember in one part.....and then splitt it on the floor , not in the car....
i have to to this in mine car, nearly the same car, i cant take the front plate of either....

[baltiboyS2]

Just incase you are wondering bellhousing?? spacer you don't have one with the gearbox i sent you as you did not need it as you are coverting to single mass flywheel

cheers Raj