Volkswagen Type II Transporter 1200 Series Shop Manual page 23

Oversize gudgeon pins (marked green) are available in
cases where the piston pin hole diameter exceeds .7874".
The practice of heating the piston is permissible where the
gudgeon pin is not a finger-push fit when the piston is cold.
It is essential to ensure that gudgeon pin circlips are
correctly located in their grooves, and that piston rings are
installed on the pistons by use of a ring tool to avoid stress
or fracture of the rings.
Lubricate . with engine oil all components durjng
assembly and ensure that a very high degree of cleanliness is
maintained.
TO REMOVE AND INSTAL CYLINDERS
( 1) Remove the cylinder headas described previously.
(2) Detach the valve push rods and push rod tubes. ·
(3) Remove the deflector plates located below the
cylinders. .
(4) Mark the cylinders and corresponding pistons so
that they can be installed in their original positions;
withdraw the cylinders from the pistons and engine
assembly.
Instaliation· is a reversal of the removal procedure with
particular attention to the folloWing points:
(1) Check the cylinder for wear and, if necessary,
replace the cylinder and piston With another assembly of
the same size and with the cylinder and piston matched.
NOTE: The cylinder seating surface on the crankcase,
cylinder contact face and gasket must be perfectly clean.
Distortion of the cylinder may result if foreign matter is
present on the surfaces. Always use a new gasket between
the cylinder and crankcase.
(2) Lubricate with engine oil the gudgeon pin and
piston surfaces.
(3) Ensure that the oil scraper ring gap is at the top
with the remaining piston ring gaps staggered. Compress the
rings, to facilitate entry into the cylinder, With a ring
compressing tool.
(4) Lubricate the cylinder walls and slide the cylinder
over the piston until the rings are fully entered in the bore,
remove the ring compressor and push home the cylinder:
NOTE: The crankcase studs must not be in contact with
the cylinder cooling fins.
(5) Instal the deflector plates below the cylinders,
bending them if necessary to· obtain a tight fit at the
crankcase studs to prevent rattling.
(6) Fit new seals to the push rod tubes and instal them
with the tube seam facing upwards. If necessary stretch the
tubes to 7.11" -7.16" to ensure positive
sealing~
but use
care to avoid cracking the tubes.
23
Engine-17
SEAL--
TUBE-
PUSH ROO
SEAL-e
Push
Rod and
Tube
Components.
TO REMOVE AND INSTAL PISTONS AND RINGS
(1) Rernove the cylinders as described previously.
(2) Mark the pistons to ensure that they are installed in
their original positions and With the appropriate cylinder.
(3) Using circlip pliers, remove the gudgeon pin
retaining circlips at the piston ends.
(4) Heat the piston to approximately 180°F using
a
suitable wrap around element or the special tool for. this
purpose.
(5) With the piston supported, push out the gudgeon
pin using a drift of the same diameter as the gudgeon pin.
(6) If it is necessary to remove the piston rings, use a
piston ring tool for this operation to avoid damage to the
rings or piston.
Installation is a reversal of the removal procedure with
particular attention to the folloWing
poin~s:
( 1) Free the piston of all carbon deposits on the crown
and in the ring grooves.
NOTE: Do not use a sharp tool for this operation or
damage to the piston surface will result . .
(2) Examine the piston skirt for carbon deposits, a
build up of carbon on one side of the piston would indicate
the possibility of a twisted connecting rod. Remove the
carbon deposits using a fine oiled corundum stone. ·