Volkswagen Type II Transporter 1200 Series Shop Manual page 30

24-Engine
connecting rod is not interchangeable with the older type
because of the weight difference.
From January 1967, Chassis No 217088359, (Engine
No H0703231), a crankshaft with an additional oil passage
permitting)he flow of oil from main bearings Nos 1 and 3
to the connecting rod bearings is installed in all engines
except the 1200cc. Due to the increased oil flow to the
connecting rods modified piston rings are fitted to prevent
an increase in oil consumption. The new crankshaft can be
service installed in other engine types but modified piston
rings and flywheel/crankshaft seal will be necessary.
TO REMOVE AND INSTAL
(I) Dismantle the crankcase as described previously.
(2) Remove camshaft and crankshaft from crankcase
half casing.
Installation is a reversal of the removal procedure with
particular attention to the following points:
(1) Ensure that there are no sharp edges or burrs on the
edges of the crankcase bearing bores; If necessary chamfer
slightly.
(2) Check that the crankshaft oilways are free of
obstruction and sharp edges.
(3) Remove any foreign matter embedded in the main
bearings, but take care not to damage or remove metal from
the bearing face.
(4) Check that the dowel pins are tight and in
serviceable condition.
(5) Position No 2 main bearing half shell in the
crankcase location, and slide into position No 1 main
bearing with the dowel pin hole towards the flywheel.
(6) With Nos 3 and 4 main bearings still in position on
the crankshaft, lubricate the bearings and instal the
crankshaft, locating the dowel pins in the bearings.
TO DISMANTLE AND ASSEMBLE CRANKSHAFT
(1) With the crankshaft removed from the engine as
already described, remove No 1 main bearing.
(2) Take out the Woodruff key at the timing gear end
of the crankshaft and remove the oil thrower.
(3) Pull off No 4 main bearing and, using circlip pliers
remove the distributor drive gear retaining circlip.
( 4) Remove the distributor drive gear, spacer, and
crankshaft timing gear, using a suitable puller for the latter.
NOTE: To facilitate removal and to avoid damage to the
seating surfaces, immerse the gears in oil heated to
approximately 180° F. Light signs of seizure can be
removed,· provided the press fit of the gears to the shaft is
not affected.
30
(5). Pull off No 3 main bearing from its crankshaft
location.
( 6) Loosen off and remove the connecting rods keeping
each bearing cap with its corresponding rod . .
Assembly is a reversal of the dismantling procedure
with particular attention to the following points:
(1) Check the crankshaft for wear and run-out, carry
out a ringing test for cracks. If necessary regrind or renew
the crankshaft, fitting the appropriate new main bearings.
Clean the crankshaft and check that all oil passages are free
of obstruction.
(2) Check the flywheel dowel holes in the end face of
the crankshaft for wear.
(3) Check the distributor drive gear and the crankshaft
timing gear for wear and tooth contact.
(4) Lubricate No 3 main bearing with engine oil and
instal on the crankshaft.
(5) Instal the Woodruff key for the gears in position in
the crankshaft. Heat the gears in oil to about 180°F and fit
to the crankshaft with the spacer. Check the gears for
secure seating when they have cooled down.
(6) Fit the distributor drive gear retaining circlip,
taking care not to damage the crankshaft journal. Lubricate
with engine oil and instal No 4 main bearing.
NOTE: No 4 main bearing must be installed with the
annular groove in the running surface towards the oil
thrower.
(7) Position the oil thrower on the crankshaft with the
concave face towards the crankshaft pulley. Insert the
Woodruff key into its location.
(8) Instal the connecting rods and tighten the bolts to
the specified torque.
·NOTE: The 53 bhp 1500cc connecting rod bolts are also
fitted with hexagon nuts, which should be tightened to a
torque of 25ft/lb.
TO CHECK CRANKSHAFT END FLOAT
Crankshaft end float is measured when the engine is
assembled and the flywheel fitted. End float should be
between .0028" and .0047" with a wear limit of .006".
(1) Attach a dial indicator to the crankcase with the
plunger bearing on the flywheel.
(2) Tap the crankshaft fully home into the engine, zero
the dial indicator and tap the crankshaft out the other way.
Check the reading on the dial indicator to .establish the
end-float.
TO ADJUST CRANKSHAFT END FLOAT
(1) Instal flywheel to the crankshaft fitting two shims
and the paper or metal gasket, do not fit the seal at this
point.
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