New old Syncro - replacing engine

1

I have managed to get myself a 90 Syncro that has a Pop top but a hole in the engine. I have a second hand 2.1 engine out of a Syncro on the way from SA. 

This is the first water cooled VW I have owned or worked on so I am starting fresh and have noticed a few posts around re water pipes faults and fuel tank requiring attention/cleaning so since the engine will be out are these things I should probably address prior to fitting the new engine.

This car has been sitting still for over 2 years but is in pretty good shape, no major rust to speak of only light surface rust in a couple of places, CV boots all look in good shape and appears that it should go through rego without much hassle.

The coolent is green (not sure if this is correct) will refill with correct coolent regardless so if this is the wrong coolent I will have to flush the system...  Hoping a garden hose running until clear will be enough..

I thought that I'd drop all oils from diff and GB and refill with suggested oils.

I have not checked the water pipes yet but am I just as well to replace them now with SS ones?

And is it a good idea to drop the fuel tank and clean/check it now?  especially since it has been sitting.


So which of these should I consider doing now and please add to the list of must do jobs.

1. Fuel tank removal and clean?

2. Coolent system flush? (I'll prob do regardless)

3. Water Pipe replacement with SS?

4. New recommended fluids (definite)

5. Clutch?


Peter




  

2

The old engine is now out and the new second hand engine (Thanks Hans) cleaned up and is ready to go in...  :)

I have swapped out heaps of air cooled dub engines in the past and gee these water cooled are a lot more difficult.  How many water hoses can there be.? :(

Anyway I have gotten half way there so all is going great guns...

 
I have attached a couple of pics showing the gantry I fashioned to remove and install the new engine and a pic of why the engine needed replacing in the first place, you may see a piece of BE rod next to the hole...   ooops

I am learning a lot and I am starting to appreciate the Syncro.. 

3
Looking good Peter.  I am finding these vehicles very complex too compared to my old air cooled T2. 
Those wheels don't look like Syncro wheels, are they the ones it came with?

Neil.


From: "richo1166@yahoo.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: Syncro_T3_Australia@yahoogroups.com
Sent: Monday, 10 October 2016, 10:53
Subject: [Syncro_T3_Australia] Re: New old Syncro - replacing engine [3 Attachments]

 
The old engine is now out and the new second hand engine (Thanks Hans) cleaned up and is ready to go in...  :)
I have swapped out heaps of air cooled dub engines in the past and gee these water cooled are a lot more difficult.  How many water hoses can there be.? :(
Anyway I have gotten half way there so all is going great guns...
 
I have attached a couple of pics showing the gantry I fashioned to remove and install the new engine and a pic of why the engine needed replacing in the first place, you may see a piece of BE rod next to the hole...   ooops
I am learning a lot and I am starting to appreciate the Syncro.. 


4

Hi Neil,


Yes everything is as I got it,  has 14" Wheels atm and I intend to go to 15" and a set of BFG AT's if at all possible later.  But my piriority atm is to get it running and registered before I start making any changes...


Then it is getting a complete fitout inside with inbuilt fridge, stove, sink, curtains etc.  I will either have to source or make a under floor water tank, ax battery, solar etc etc etc    lots of fun...


Then I'll attack the running gear and paint..  Love to get a decoupler and diif lock but my transaxle does not have the boss for a diff lock so either I'll have to try and source another transaxle our adapt this transaxle so it can take one... new front bar and rear bar. 

I took the bar off that back and it looks like one that was on the Telstra Syncros gee it is HEAVY - honestly weighs near the same as the Kaymar bar with wheel carrier on my 80 Landcruiser,  it is not going back on.....!


I spent 16years working on my Landcruiser turning it into extremely capable 4x4 and now I feel like I am starting at ground zero again, having said that I know what I want to do with this car and plan to take years to do it piece by piece..


Peter



5
Hi Peter,

I may be interested in that rear bar,

Neil.


From: "richo1166@yahoo.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: Syncro_T3_Australia@yahoogroups.com
Sent: Tuesday, 11 October 2016, 9:44
Subject: Re: [Syncro_T3_Australia] Re: New old Syncro - replacing engine

 
Hi Neil,

Yes everything is as I got it,  has 14" Wheels atm and I intend to go to 15" and a set of BFG AT's if at all possible later.  But my piriority atm is to get it running and registered before I start making any changes...

Then it is getting a complete fitout inside with inbuilt fridge, stove, sink, curtains etc.  I will either have to source or make a under floor water tank, ax battery, solar etc etc etc    lots of fun...

Then I'll attack the running gear and paint..  Love to get a decoupler and diif lock but my transaxle does not have the boss for a diff lock so either I'll have to try and source another transaxle our adapt this transaxle so it can take one... new front bar and rear bar. 
I took the bar off that back and it looks like one that was on the Telstra Syncros gee it is HEAVY - honestly weighs near the same as the Kaymar bar with wheel carrier on my 80 Landcruiser,  it is not going back on.....!

I spent 16years working on my Landcruiser turning it into extremely capable 4x4 and now I feel like I am starting at ground zero again, having said that I know what I want to do with this car and plan to take years to do it piece by piece..

Peter




6

Neil,

It will be put up behind my shed and left there, so next time you are down Canberra way you can pop in and take it with you.. :)

Peter

7
Need to put some silicon on that hole. The mice will get out. 

Regards
Steve

On 11 Oct 2016, at 13:18, richo1166@yahoo.com.au [Syncro_T3_Australia] <Syncro_T3_Australia@yahoogroups.com> wrote:

 

Neil,

It will be put up behind my shed and left there, so next time you are down Canberra way you can pop in and take it with you.. :)

Peter

8
Hi Peter,

Thanks for that, happy to pay for it, will let you know when I can get down there,

Neil. 


From: "richo1166@yahoo.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: Syncro_T3_Australia@yahoogroups.com
Sent: Tuesday, 11 October 2016, 13:18
Subject: Re: [Syncro_T3_Australia] Re: New old Syncro - replacing engine

 
Neil,
It will be put up behind my shed and left there, so next time you are down Canberra way you can pop in and take it with you.. :)
Peter


9

I had a great weekend.

I got the engine in and I was pleasently surprised how straight forward it was. It started up straight away on 2 year old fuel.  I have since drained most of it out as the tank was 3/4 fill so I will take some more out before refilling with new 98. 

Gee it is quiet and even though it had rubish fuel ran OK (but not perfect). Driveline sounded awesome no weird noises etc. 

Being the first time driving a Syncro it seemed so nice to drive smooth and really surprise (again) how well it felt on the road. 

Also I have just straight water in the cooling system atm and will get some raditor flush this week dump it and replace with G12 that I have ready to go..  Also looking at a set of stainless pipes as there was so much rust in the cooling as is it I can only imagine what those pipes are like.

I have to replace the fuel filter but looks like a pita job so another job for this week...

Anyway again thanks Hans for the engine she is a cracker.

 



10
Looks great.

You have the camperize roof system which is excellent quality and design.

Great work with the engine install.

How is the interior?

Cheers,

Skot

On 17/10/2016 7:58 AM, richo1166@yahoo.com.au [Syncro_T3_Australia] wrote:

I had a great weekend.

I got the engine in and I was pleasently surprised how straight forward it was. It started up straight away on 2 year old fuel. I have since drained most of it out as the tank was 3/4 fill so I will take some more out before refilling with new 98.

Gee it is quiet and even though it had rubish fuel ran OK (but not perfect). Driveline sounded awesome no weird noises etc.

Being the first time driving a Syncro it seemed so nice to drive smooth and really surprise (again) how well it felt on the road.

Also I have just straight water in the cooling system atm and will get some raditor flush this week dump it and replace with G12 that I have ready to go.. Also looking at a set of stainless pipes as there was so much rust in the cooling as is it I can only imagine what those pipes are like.

I have to replace the fuel filter but looks like a pita job so another job for this week...

Anyway again thanks Hans for the engine she is a cracker.




--
Best regards, Scott Pitcher SPB Consulting
11
Hey Richo,

that'd be the engine from my Old silver Caravelle. Always was a strong motor. Maintained regularly. Just throw some injector cleaner in her every 2000 km and only 95 / 98 RON and it should go for another 10 years.

Mark
12
Hey Mark, 

Well it is a good one I have to say. Runs really nice in the driveway.  Yet to test it out on the road for real.

One thing anyone could answer :::

I found a spare plug and wires that looks like it should plug in to the engine somewhere around under the air cleaner.  I have the plug into the air cleaner so it isn't it, but this one has the same plug but a round rubber dust cover...  pulling my hair out. I don't know how helpful that pic is.. sory.

Peter

Btw the pic I took before I pulled everything apart shows the wire coming out from under the air cleaner inlet pipe bent back towards the front of the syncro I just don't have a pick of what the plug os plugged into.
13
Maybe it plugs into the idle stabiliser right next to the throttle body on top of the engine.

It has a plug about that size?

Cheers,

Skot

On 20/10/2016 7:51 PM, richo1166@gmail.com [Syncro_T3_Australia] wrote:

Hey Mark,


Well it is a good one I have to say. Runs really nice in the driveway. Yet to test it out on the road for real.

One thing anyone could answer :::

I found a spare plug and wires that looks like it should plug in to the engine somewhere around under the air cleaner. I have the plug into the air cleaner so it isn't it, but this one has the same plug but a round rubber dust cover... pulling my hair out. I don't know how helpful that pic is.. sory.

Peter

Btw the pic I took before I pulled everything apart shows the wire coming out from under the air cleaner inlet pipe bent back towards the front of the syncro I just don't have a pick of what the plug os plugged into.

--
Best regards, Scott Pitcher SPB Consulting
14
It's the diagnosis plug. It mounts on the back of the alternator but does not connect to anything. 

Sent from Greg's iPhone

On 20 Oct 2016, at 8:16 PM, Scott Pitcher spbconsulting@bigpond.com [Syncro_T3_Australia] <Syncro_T3_Australia@yahoogroups.com> wrote:

 

Maybe it plugs into the idle stabiliser right next to the throttle body on top of the engine.

It has a plug about that size?

Cheers,

Skot

On 20/10/2016 7:51 PM, richo1166@gmail.com [Syncro_T3_Australia] wrote:
 

Hey Mark, 


Well it is a good one I have to say. Runs really nice in the driveway.  Yet to test it out on the road for real.

One thing anyone could answer :::

I found a spare plug and wires that looks like it should plug in to the engine somewhere around under the air cleaner.  I have the plug into the air cleaner so it isn't it, but this one has the same plug but a round rubber dust cover...  pulling my hair out. I don't know how helpful that pic is.. sory.

Peter

Btw the pic I took before I pulled everything apart shows the wire coming out from under the air cleaner inlet pipe bent back towards the front of the syncro I just don't have a pick of what the plug os plugged into.

--
Best regards, Scott Pitcher SPB Consulting

15
Take a photo of the top of your engine as it is now. That will help.

It doesn't look like the diagnostic plug ( that fits to the alternator) to me - that plug is round.

Cheers,

Skot

On 20/10/2016 7:51 PM, richo1166@gmail.com [Syncro_T3_Australia] wrote:

Hey Mark,


Well it is a good one I have to say. Runs really nice in the driveway. Yet to test it out on the road for real.

One thing anyone could answer :::

I found a spare plug and wires that looks like it should plug in to the engine somewhere around under the air cleaner. I have the plug into the air cleaner so it isn't it, but this one has the same plug but a round rubber dust cover... pulling my hair out. I don't know how helpful that pic is.. sory.

Peter

Btw the pic I took before I pulled everything apart shows the wire coming out from under the air cleaner inlet pipe bent back towards the front of the syncro I just don't have a pick of what the plug os plugged into.

--
Best regards, Scott Pitcher SPB Consulting
16

There are a few connections that use that style plug. The closest to the air cleaner is in the connection between the case breather and the inlet boot


17
Attachment didn't work last time.
18
Power steering plug?
19
Sorry I didn't see the photo. Definitely not the diagnosis plug. 

Sent from Greg's iPhone

On 21 Oct 2016, at 6:04 AM, plander@optusnet.com.au [Syncro_T3_Australia] <Syncro_T3_Australia@yahoogroups.com> wrote:

 

Power steering plug?

20
The breather unit is the only thing with that plug around there but the boot is wrong. image1.JPG
Gregor 
Sent from Greg's iPhone

On 21 Oct 2016, at 7:24 AM, gregespo73@yahoo.com [Syncro_T3_Australia] <Syncro_T3_Australia@yahoogroups.com> wrote:

 

Sorry I didn't see the photo. Definitely not the diagnosis plug. 

Sent from Greg's iPhone

On 21 Oct 2016, at 6:04 AM, plander@optusnet.com.au [Syncro_T3_Australia] <Syncro_T3_Australia@yahoogroups.com> wrote:

 

Power steering plug?