Volkswagen Type II Transporter 1200 Series Shop Manual page 26

20-Engine
Oversize gudgeon pins (marked green) are available in
cases where piston pin hole diameter exceeds .8662" -
l500cc and .7874"- 1200cc.
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 piston ring tool to avoid
stress or fracture of the rings.
Lubricate with engine oil all components during
assembly and ensure that a very high degree of cleanliness is
maintained.
From August 1965, Chassis No 216000001 (Engine .No
HOOOOOOl) cylinders have nineteen cooling fins and can be
exchanged and matched with former cylinders. The piston
rings are .078" thick and the upper ring has. an annular
groove which is fitted with Sintered Ferrox.
TO REMOVE AND INSTAL CYLINDERS
(1) Remove the cylinder heads as 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.
Installation is a reversal of the removal procedure with
particular attention to the following points:
(1) Check the cylinder for wear and, if
neces~ary
replace the cylinder and piston with another assembly of
the same size and with the cylinder and piston matched.
(2) Check that the cylinder seating face on the
crankcase, cylinder shoulder and gasket are 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.
(3) Lubricate with engine oil the gudgeon pin and
piston surfaces.
(4) Ensure that the oil scraper ring gap is at the top
with the remaining piston ring gaps equally staggered.
Compress the rings with a piston ring compressing tool to
facilitate entry into the cylinder.
(5) 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.
(6) Instal the deflector plates below the cylinders,
bending them if necessary to obtain a tight fit at the
crankcase studs to prevent rattling.
26
(7) Fit new seals to the push rod tubes and instal them
with the tube seam facing upwards. If necessary stretch the
tubes to 7.1" -7.15" for 1200cc, and 7.48" -7.52" for
1500cc. This will ensure positive sealing, but use care to
avoid cracking the tubes.
TO REMOVE AND INSTAL PISTONS AND RINGS
( 1) Remove 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 bore 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 pin.
(6) To avoid damage to the piston rings or piston
during removal of the rings, use a piston ring tool for this
operation.
Installation is a reversal of the removal procedure with
particular attention to the following points:
(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 may result.
(2) Examine the piston skirt for carbon deposits,
irregular carbon build up would indicate the possibility of a
twisted connecting rod.
(3) Remove the carbon from the piston skirt by using
an oiled fine corundum stone. Do not use emery cloth.
(4) Check the pistons for wear and if necessary replace
them with pistons of the same size and weight.
(5) Check the piston
rin~s
for gap and side clearance
(see specifications); as described at the begimting of this
section.
(6) Instal the gudgeon pin circlip at the side of the
piston which faces the flywheel. · ·
NOTE: Pistons must be installed with the a"ow or word
VORN stamped on the crown pointing to the flywheel.
(7) Instal the piston on the connecting rod, heating the
piston as described earlier if the gudgeon pin is 'not a push
fit.
(8) Insert the i"emairting pin circlip and check that both
circlips are correctly seated
irl
the piston grooves.