Volkswagen Type II Transporter 1200 Series Shop Manual page 15

(4) Loosen off and detach the cover plate above the
crankshaft pulley.
(5) Take out the securing screws and remove the
manifold preheater pipe sealing plate.
{6) Loosen off and detach the rear engine cover plate.
(7) Loosen off heat exchanger clamps and the clips
connecting the warm air channels.
(8) Unscrew and remove the securing nuts attaching
the silencer flanges to the cylinder heads, and take off the
pre-heater adaptor pipe.
(9) Take out the four screws in the manifold pre-heater
pipe.
{10) Remove the silencer and gaskets.
{II) Release the securing nut on the generator shaft
pulley and remove the nut, spacers, outer pulley half and
the fan belt.
{12) Disconnect the cables connecting the ignition coil
to the distributor' pull free the connectors at the spark
plugs and remove the distributor cap.
{13) Take out the securing screws located at each side
of the fan housing, unhook the air control return spring and
take out the throttle ring securing screws.
NOTE: On later models fitted with modified air control
system, remove the right rear lower warm air duct and
remove the thermostat securing screw. Unscrew and detach
the thermostat from the end of the connecting link and lift
the fan housing and generator from the engine.
{14) Loosen off and remove the strap securing the
generator to the mounting on the engine and remove the
fan housing and generator complete from the engine.
{I 5) Remove the intake manifold and intermediate
exhaust flange securing nuts, detach the manifold and
remove the cylinder head sealing rings.
{16) Take out the screws in lower part of warm air
channel and remove the exhaust pipe clamps. Remove the
heat exchangers by easing forward.
(I 7) Remove both air guide plates and take off the
cylinder cover plates.
{18) Loosen and remove the crankshaft pulley securing
bolt, using a suitable puller withdraw the pulley frorri the
end of the crankshaft.
{19) Take out the securing screws and' remove the
lower crankshaft pulley cover plate.
{20) Ease off the cylinder head cover n:itairiing clips
and remove the covers.
{21) Loosen off evenly the rocker arm shaft securing
nuts and remove the rocker shaft assembly. Take out the
stud seals.
· {22) Withdraw the push rods from the cylinder heads.
{23) Loosen off and remove the cylinder heads
retaining nuts and washers and withdraw the cylinder heads
from the studs. ·
15
Engine-9
{24) Detach the push rod tubes and the deflector plates
from below the cylinders.
(25) Ease the cylinders away from the block and off
the studs.
NOTE: Mark piston crowns and cylinders to ensure
installation in the original positions.
{26) Using circlip· pliers, take out tpe gudgeon pin
retaining circlips from the pistons.
{27) If the gudgeon pins cannot be finger pushed from
the pistons, heat the piston using a wrap around element or
the special tool for this purpose.
(28) With the piston fully supported, push
but
the
gudgeon pin using a drift of the same diameter.
{29) Loosen off and remove the three oil cooler
retaining nuts and remove the cooler and gaskets.
{30) Remove the oil pump cover and · gasket after
unscrewing the securing nuts.
{31) Take out the pump gears and withdraw the pump
body using the special extractor for this purpose.
{32) Loosen off and remove the oil filter securing nuts
at the base of the crankcase and remove the cover plate,
gaskets and oil filter.
{33) Remove the fuel pump securing nuts and. detach
the pump, remove the flange, gaskets and pump push rod.
{34) Remove the distributor by releasing the retainer
nut.
· {35) Take out the coil spring from the centre of the
distributor drive pinion.
{36) Turn the crankcase assembly upside down to
allow the drive shaft and washer to fall from the casmg.
{37) Loosen off and remove the clutch assembly and
retaining bolts from the flywheel.
{38) Using the special wrench and flywheel retainer
tool, remove the flywheel gland nut and detach the
flywheel. Remove the crankshaft. oil seal at the flywheel
end of the crankshaft.
{39) Remove the oil pressure switch from the
crankcase. 1
(40) Pull off the oil filler connecting hose and take out
the threaded ring to detach the oil filler.
{41) To keep the tappets in position in the right
crankcase half, instal the special retaining springs for this
purpose.
{42) Loosen off and remove the nuts retaining together
the two crankcase halves and using a rubber mallet gently
. tap the right half of the crankcase to separate it from the
left. ·
NOTE: Do not insert levers or tools between the joint faces
of the casing halves.
(43) Remove the camshaft end plug, camshaft and
tappets from the casing.