Volkswagen Type II Transporter 1200 Series Shop Manual page 37

necessary slightly chamfer the outer edge with a scraper to
facilitate entry of the new seal. ·
(5) Apply a coat of sealing compound to the oil seal
recess and instal the new seal. Ensure that the seal is seated
squarely at the base of the recess.
(6) Lubricate with oil the flywheel flange on which the
seal bears and instal the flywheel.
1200/1500/1600 MOnRI,S FROM }ANVARY,
'6.~
Four dowels and a gland nut are used to position and
secure the flywheel to the crankshaft. Located between the
flywheel and crankshaft is a paper or metal gasket
depending upon flywheel type. An oil seal recessed in the
crankcase No 1 main bearing bears on the shoulder of the
flywheel to form a seal. From April 1966, Chassis No
216139032 (Engine No H0140936) the metal seal between
the flywheel and crankshaft is replaced with a rubber seal,
at the same time the crankshaft, flywheel and shims for
end-float adjustment have been modified.
The main drive shaft spigot is supported by a needle
bearing located within the gland nut. From May 1966,
Chassis No 216149910 (Engine No H0153536) all engines
have been installed with a modified gland nut of increased
length. The modified nut can be installed in all engines
except the 30 and 36 bhp.
To maintain engine balance, the crankshaft, flywheel
and clutch are marked with paint at their heaviest points.
On assembly if all three components are so marked the
marks should be located 120 degrees apart, where only two
components are marked, the marks should be 180 degrees
apart.
Location of marks as follows:-
(a) Crankshaft - Paint dot in the threaded hole for
the gland nut.
(b) Flywheel -Paint dot and .200" hole on the face
which is toward the clutch.
CRANKSHAFT ASSEMBLY
Crankshaft and Flywheel Removed to Show End Float
Adjusting Shims and Oil Seat at No 1 (Flywheel end) Main
Bearing.
Engine-31
(c) Clutch - Paint line on the outer edge of the
pressure plate.
From August 1966, Chassis No 217000001 (Engine No
H0183373) the outside diameter of the flywheel has been
increased by .1 57", also the number of teeth has been
increased to 130 instead of 109. The transmission housing
has been modified as a result of the increased flywheel
diameter, and the hole for the starter pinion shaft has been
reduced to accommodate the new starter. Installation of
the new flywheel can only be made to previous engines
when the starter and transmission of new design are fitted.
TO REMOVE AND INSTAL FLYWHEEL
(1) Loosen off evenly and progressively the clutch
securing bolts and detach the pressure plate and driven
plate assembly.
(2) Loosen off and remove the flywheel gland ni.lt and
flywheel using the special wrench and flywheel retainer
tool.
Installation is a reversal of the removal procedure with
particular attention to the following points:
(1) Check the flywheel teeth for wear and damage, if
necessary the ring gear can be machined .080" on its clutch
side to remove slight damage to the teeth. New 45 degree
chamfers should be machined on the teeth after the initial
machining.
(2) Check the dowel holes in the flywheel and
crankshaft for wear, and replace the dowels if necessary.
(3) Ensure that the needle bearing in the gland nut is in
serviceable condition and not worn. Lubricate the bearing
with a small quantity of universal grease.
(4) Adjust the crankshaft end-float as specified.
(5) Instal the metal gasket and flywheel tightening the
gland nut to a torque of 217ft/lb.
(6) Check that the flywheel run-out if any does not
exceed the maximum of .012".
OIL SEAL
\
~I
LOCK WASHER
I
0~
GLAND NUT
END FLOAT SHIMS
37