Volkswagen Type II Transporter 1200 Series Shop Manual page 32

26-Engine
halves during tightening by light hammer taps applied at the
sides of the connecting rod.
NOTE: Connecting rod bearings should not at any time be
scraped, reamed or filed. When lubricated the connecting
rods must fall smoothly through 180° under their own
weight.
(7) Using feeler gauges, check the axial float of the
connecting rods on the crankshaft journal.
(8) Lock the connecting rod securing bolts into
position by peening with a peening chisel.
TO RECONDITION CONNECTING RODS
(1) With the connecting rods removed from the engine
press out the gudgeon pin bearings using the special tool for
this purpose.
(2) Press in the new gudgeon pin bearings and ream to
an inner diameter of:
1200cc Pin with black dot:- .7874" -.7876"
Pin with white dot:- .7877" -.7879"
1500cc Pin with black dot:- .8661" -.8664"
Pin with white dot:- .8664" -.8667"
NOTE: Ensure that the bearing bore after reaming is free of
scores and chatter marks. 1 'he gudgeon pin should be a light
finger push fit in the. bearing, when in a dry state and at
room temperature.
(3) If necessary drill the oil passages in the new
bearing.
(4) Carry out a connecting rod alignment check and
ensure that both bearings are parallel to each other.
7. CAMSHAFT
1200 MODELS TO JANUARY, 1963
From Chassis No 624263 (Engine No 5009585) on the
40 bhp engine a modified camshaft together with modified
cam followers is installed. This modification can be carried
out to engines from Engine No 3400000, but it is
important that the modified cam followers are fitted with
the new camshaft.
Push rods of the previous shortened type can be
installed in all engines manufactured since May 1959. If it is
found that the rocker arm rests on the valve stem without
any clearance adjustment available, it will be necessary to
grind the rocker ann slightly.
In addition the following modifications have been
carried out:
(a) From Engine No 5067818 due to camshaft
modifications the end float has been increased to
.0024" -.0045", as against .0012" -.0033" for
earlier models. Wear limit is .0055".
(b) From Engine No 5M2820 an annular oil groove
i~
·
provided at the camshaft thrust bearing in the
crankcase. .
(c) From Engine No 3464486 the camshaft thrust.
surface in · the crankcase has been increased to
1.496" from I.4I7".
TO REMOvE AND INSTAL
(I) Dismantle the crankcase as described earlier.
(2) Remove camshaft end plug and camshaft fromthe
crankcase half. Note the timing marks on the gears.
Installation is a reversal of the removal procedure with
particular attention to the following points:
(I) Check that the timing gear is securely riveted to the
camshaft and that no free movement exists at the joint.
(2) Cam faces and camshaft bearing points must be
smooth and square, and free from wear ur scoring.
(3) Remove any burrs from the cam edges or slight
damage to the faces by use of a fine grain oil stone.
(4) Check the camshaft for run-out and the camshaft
timing gear for wear and correct tooth contact.
(5) Lubricate with engine oil the bearing journals and
cams; instal the camshaft engaging the tooth marked 0
between the two teeth of the crankshaft timing gear which
are C(:!ntre punched.
(6) Check the backlash of the camshaft timing gear by
moving the gears back and forth, gradually turn the
camshaft until all teeth have been meshed and ~hecked.
Specified backlash of camshaft timing gear is .0020":
NOTE: Camshafts are available with timing gears of seven
different sizes to enable the specified backlash to be
obtained. Sizes are marked on the timing gears in digits
indicating in one hundredth of a millimeter, the variation
from the standard pitch radius.
1200/1500/1600 MODELS FROM JANVARY, '63
. . . . .
From August 1965, Chassis No 21600000I (Engine No
HOOOOOOl) the camshaft is mounted in three leadccoated
. ste~l bearings of the split type: Shoulders are provided at
No 3 bearing to take the camshaft thrust. These bearings
cannot be serVice installed in previous crankcases.
32
TO REMOVE AND INSTAL
(I) Dismantle the crankcase as described earlier.
(2) Remove camshaft end plug·arid camshaft from the
crankcase half. Note the timing marks on the gears.
NOTE: On engines fitted with detachable camshaft bearing
shells, take out the shells.