Motor & Transmission Installation with Motor Cradle Factory Style.

[schwarzwaldsprinter]

Hello,
Got my 2002 T1N on the lift and the engine & Transmission ready soon to go back in.
I was thinking to remove the motor cradle together with the suspension, rebuilt it, and then install it with motor and Transmission together from the bottom- like they are assembling it in the Factory.
Anyone who has done it that way, and what do I need to look out for?

The advantage is that I can install all the other items like ac, blower fan etc before installing the motor.
Any advise is appreciated.
Thanks!

Sven

 

[Midwestdrifter]

The subframe isn't really designed to support the engine by itself. The factory tooling installs the engine/trans complete, and it supports the back of the trans at the same time. Attempting to move the subframe with the engine alone, and being supported by the two engine mounts, could result in the mounts tearing, and the engine being liberated.

Even if you were to do that, you would need to fab up some tooling to support everything. Knuckles/struts, and the back of the trans to start.

These vehicles are quite reasonable to install/remove the engine/trans. Remove the cooling stack (radiator/intercooler). If you don't want to evacuate the AC, you can unbolt the compressor and swing it out of the way with the condenser, and support it to the side.

Remove the AC duct assembly from above the engine, (its 6 nuts on the firewall).

Now you can disconnect all the hoses, the exhaust, and the driveshaft.

From there the engine/trans can be attached to a hoist/crane and pulled out the front.

 

[schwarzwaldsprinter]

The subframe isn't really designed to support the engine by itself. The factory tooling installs the engine/trans complete, and it supports the back of the trans at the same time. Attempting to move the subframe with the engine alone, and being supported by the two engine mounts, could result in the mounts tearing, and the engine being liberated.

Even if you were to do that, you would need to fab up some tooling to support everything. Knuckles/struts, and the back of the trans to start.

These vehicles are quite reasonable to install/remove the engine/trans. Remove the cooling stack (radiator/intercooler). If you don't want to evacuate the AC, you can unbolt the compressor and swing it out of the way with the condenser, and support it to the side.

Remove the AC duct assembly from above the engine, (its 6 nuts on the firewall).

Now you can disconnect all the hoses, the exhaust, and the driveshaft.

From there the engine/trans can be attached to a hoist/crane and pulled out the front.

As I stated, I will install the motor and the transmission together like in the factory. The motor cradle is designed to support the motor, this is where the engine mounts are located. Transmission and motor combined are a 3 Point mount. The only thing that needs to be watched for at installation is the alignment of the struts. Not to big a deal.

I will snap pictures and will post it here.

 

[schwarzwaldsprinter]

Finally be able to continue:

The table will serve as a support for subframe, engine and transmission

 

[schwarzwaldsprinter]

Cleaned up and corrosion treated.
New motor mounts installed.
Ready to receive the engine and transmission.

Final corrosion protection will be applied once all is together and van is running.

 

[Green-Schlomo]

Not gonna lie, this seems like it has potential to result in disaster. Just be careful nothing gets hung up when lifting the engine into the truck so that it doesnt end up falling off that hoist.

 

[schwarzwaldsprinter]

Not gonna lie, this seems like it has potential to result in disaster. Just be careful nothing gets hung up when lifting the engine into the truck so that it doesnt end up falling off that hoist.

Thanks for the advise. I made sure to place suppport in the back.

 

[schwarzwaldsprinter]

Finished the engine and installing the accessory drives.

 

[schwarzwaldsprinter]

Installed engine on motor mounts in subframe.

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[schwarzwaldsprinter]

….. and installed transmission…… almost ready to back in the van. Just Got to bolt on the TC, all oil lines and a few other small items.

 

[schwarzwaldsprinter]

Ready to be installed tomorrow.
I used a 12 volt fuel pump to prime the entire fuel system. So a quick start should be possible and no try running of the HPFP.

I will make a time lapse video of the install and will try to post it here.

 

[schwarzwaldsprinter]

Time has come…..

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[schwarzwaldsprinter]

- YouTube

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youtube.com

 

[lindenengineering]

Comment
That to me looks like alot of unnecessary work= Excess teardown $$$$$ Spent.
When our Mex techs with an ajudante can drop the transmission out in 0.75 hours then the engine in 1.75 max hours on to the floor.
With an alloted 2 hours labor, its well within book time which enhances the profit on the job.
Name of the game -Must stay on budget
Dennis

 

[schwarzwaldsprinter]

Comment
That to me looks like alot of unnecessary work= Excess teardown $$$$$ Spent.
When our Mex techs with an ajudante can drop the transmission out in 0.75 hours then the engine in 1.75 max hours on to the floor.
With an alloted 2 hours labor, its well within book time which enhances the profit on the job.
Name of the game -Must stay on budget
Dennis

Absolutely. I just wanted to do it this way. 😃

 

[lindenengineering]

Absolutely. I just wanted to do it this way. 😃

Just a cautionary comment .
We took one in a while back having been partially dismantled like this; the subframe fixing bolts to the frame rail inserts had been sheered off by rust./corrosion ingress.

If you must do it this way proceed with caution!
Dennis

 

[schwarzwaldsprinter]

Thank you for the advise of caution. I checked the bolts and frame. They looked really good. I also corrosion treated the entire frame and subframe.

 

[lindenengineering]

Thank you for the advise of caution. I checked the bolts and frame. They looked really good. I also corrosion treated the entire frame and subframe.

Advise
Use a good dose of American care and attention, by applying anti seize compound to the the threads upon reinstallation.
Dennis

 

[schwarzwaldsprinter]

Advise
Use a good dose of American care and attention, by applying anti seize compound to the the threads upon reinstallation.
Dennis

Great advise. I will do that tomorrow. 👌

 

[schwarzwaldsprinter]

To finish this post, I can say that I really liked this way of installing the engine. Of course, I had all the tools and time to do so. My goal was to have inspected and to have repaired all components of the front end of the vehicle - if needed, and sometimes as precautionary measures.

The engine started right up and is running very smooth.

I did take the van for a short ride at the privat airport where it is located. No issues or fault codes so far.
I also serviced the rear axle differential.

Windshield is being installed in a couple days, and then I will take it for a longer drive.

After. A few hundred miles of driving I will change out the oil and re-inspect.

Next items will be to complete the full rust protection measures, install PPF in the front and roof, new tires, new headlights, install rear camera, a new radio with a large monitor.
lastly to move the partition behind the front seats back just past the sliding door opening and to install the 3 seater Sprinter bench seat.

Thank you to all who have commented, read, and helped in this post!!

Sven. 🍻