Volkswagen Type II Transporter 1200 Series Shop Manual page 28

22-Engine
crankshaft. Heat the gears in oil to about 180°F and instal
on the crankshaft with the spacer fitted between the gears.
Check the gears for secure seating when they have cooled
down.
(5) Fit the distributor drive gear retaining ring taking
care not to damage the crankshaft journal.
(6) Using compressed air blow out all oil passages and
ensure that there is no obstruction.
(7) Instal No 4 main bearing, and the oil thrower, with
the concave face towards the crankshaft pulley, and insert
the Woodruff key,
(8) Instal the connecting rods and tighten the securing
bolts to the specified torque. Instal No 1 main bearing.
TO CHECK CRANKSHAFT END FLOAT (Engine in
Vehicle).
Crankshaft end float can be checked when the engine is
located in the vehicle by attaching a dial indicatqr on the
rearmost crankcase stud, with the plunger bearing on the
crankshaft pulley.
Obtain the end float reading by moving the crankshaft
back and forth at the pulley. End float should be from
. 0028" to .0047", the wear limit is .006".
TO ADJUST THE CRANKSHAFT END FLOAT
( 1) With the flywheel removed, push the installed
crankshaft against the flywheel side of the engine to take
up the end float.
(2) Measure the distance from .the crankshaft end face
to the outer thrust face of No 1 main bearing by inserting a
dial gauge in the flywheel seat so that it contacts the
crankshaft.
(3) Position the dial gauge on the flywheel jointing
flange and measure the depth of the crankshaft seat.
(4) To determine the thickness of shims required, take
the difference between the two readings plus the thickness
of the paper gasket in its compressed state which is .006",
the resulting figure is end float.
NOTE: Only one paper gasket should be installed. Shims
are available in different thicknesses, each shim has the
thickness etched on it. Three shims of the required
thickness are to be installed in each case.
TO INSTAL STEEL BACKED CRANKSHAFT BEARINGS.
(Engines for arctic climates)
(1) Working on the right hand crankcase half, insert the
dowel pins for main bearings Nos 2 and 3 into the
crankcase and instal the bearing shells.
28
(2) Working on the left hand crankcase half, insert all
the dowel pins in the crankcase and instal the bearing shells
for main bearings Nos 1, 2 and 3.
NOTE: The shell for No 1 bearing is installed at a slight
·angle to facilitate the
cpntPrinv
of the crankcase halves.
(3) With No 4 main bearing positioned on the
crankshaft, instal the crankshaft locating No 4 bearing on
the dowel pin.
( 4) Position the second half of No 1 bearing on the
crankshaft.
NOTE: · The oil pockets in the bearing shoulder must be
towards the flywheel.
(5) With bearings Nos 2 and 3 installed, place in
position the right hand crankcase half.
From Engine No 3520333 these bearing shells can be
service installed. However a dowel pin hole must be drilled
in the right hand crankcase half for No 3 main bearing. Use
an old No 3 ring type bearing as a template by cutting the
bearing in half so that the cut edges are level with the joint
face of the crankcase, and the dowel pin hole is exactly
vertical, but with the offset towards No 2 crankshaft
bearing .
TO REMOVE AND INSTAL CONNECTING RODS
(1) Remove the crankshaft as described earlier.
(2) Loosen off and remove the connecting rod securing
bolts and remove the rods and caps.
NOTE: Bearing caps should be kept with their
co"esponding connecting rods.
Installation is a reversal of the removal procedure with
particular attention to the following points:
(1) Check the weight of the connecting rods, to ensure
that any difference in weight of the connecting rods does
not exceed 0.18 oz otherwise engine balance will be
affected. Weight reduction can be made on heavy
connecting rods by removing metal at the points indicated
in the connecting rod illustration.
(2) Inspect the gudgeon pin bearing for wear or
damage.
NOTE: When a new bearing is installed the gudgeon pin
should be a light finger push fit at room temperature.
(3) Check the connecting rod alignment and if
necessary correct.
(4) Thoroughly clean all components prior to
· assembly; instal the bearing shells in the connecting rods
and caps, and lubricate with engine oil.
. (5) Fit the connecting rods to the crankshaft and
ensure that the identification numbers stamped on the rods
and bearing caps are at the same side.