Engine - Volkswagen Type II Transporter 1200 Series Shop Manual

ENGINE
SPECU'ICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . . .
Stroke ....
~
................. .
·Capacity . . . . . . . . . . . . . . . . . . . . . .
Bhp (max) . . . . . . . . . . . . . . . . . . . .
• 200 ENGINES
36 bhp (Early)
3.03"
2.52"
72.74 cu in
36 at 3700 rpm
36 bhp (Late)
3.03"
2.52"
72.74 cu in
36 at 3700 rpm
40bhp
3.03"
2.52"
72.72 cu in
Maximum torque ............... .
Compression ratio .............. .
56 ft/lb at 2000 rpm
6.6:1
58 ft/lb at 2400 rpm
6.6:1
4Ls at 3900 rpm
65 ft/lb at 2400 rpm
7.0:1
Ignition firing point ............. . 7.5° btdc
CRANKSHAFT
Main bearing type:
Early 36 bhp Nos 1, 3, 4
No2 ................. .
Late 36 bhp Nos 1, 2, 3 ....... .
No4 .................. .
Early 40 bhp .............. .
Aluminium alloy
bushes
Aluminium alloy
shells
Steel-backed,
lead bronze
shells
Aluminium alloy
bush
As for late
36 bhp
Late 40 bhp Nos 1, 3, 4 . . . . . . . . Aluminium alloy
bushes
No 2 . . . . . . . . . . . . . . . . . . Aluminium alloy
shells
Crankcase bore for crankshaft bearings:
Nos 1, 2, 3 bearings ..... ·. . . 2.5591 ' 7 -25598"
Except up to Engine No 3520332 2.3622" -2.3630"
No 4 all 1200 engines .. ; . . . . 1.9685" -1.9696"
*Crankshaft end float
( t N 1 b
. ) .0027" -.005"
a o eanng ......... .
Crankshaft journal nominal diameter:
Early 36 bhp Nos 1, 2, 3 and
connecting rod journals . . . . . . 1.9685"
All
other engines . . . . . . . . . . . 2.1653"
All engines, No 4 main bearing
journal . . . . . . . . . . . . . . . . . 1.5748"
~~<'No l
main bearing is adjacent to the flywheel.
7.5° btdc
10° btdc
PISTONS AND RINGS
Piston
io
cylinder clearance .....
Piston ring side clearance:
Upper compression ........ .
Except early 36 bhp ....... .
Lower compression ....... .
Oil scraper ............. .
Piston ring gap:
Compression . . . . . . . . . ... .
Oil scraper ............. .
Weight in variation between
pistons in one engine .......... .
.0018"
±
.0002"
.0031"
±
.0004"
.0024" ± .0004"
.0024"
±
.0004"
.001"
±
.001"
.000"
.015"
±
.003"
.013"
±
.003"
18 oz (max)
CONNECTING RODS
Big-end bearing clearance:
Early 36 bhp engine ....... .
Later engines ............ .
Big end bearing end float:
Early 36 bhp engine ....... .
Later engines ............ .
Gudgeon pin clearance in bush:
Early 36 bhp engine . . ..... .
Later engines ............. .
Weight variation between
connecting rods ............
~
.0008" -.0024"
.0008" -.003"
.0067" -.016"
.004" -.016"
.0004" -.001"
.0004" -.0008"
.18 oz (new)
-.36 oz (wear
limit when
repairing)
CAMSHAFT
Bearing bore for shaft ............ .
Backlash between gears ........... .
Beai:ing clearance . . . . . . . . . . . . . . . .
End play ..... · · ................ .
.9456" -.9458"
.000" - .002"
.0008" -.0021"
.0008" -.0027"
7
.9850" -.9857"
.000" - .002"
.0008" -.0021 "
.0016" -.0051"
.9850" -.9857"
.000" -.002"
.0008" -.0021"
.0016" -.0051"