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Home / Typ 1 Motor Specification

  1. Crankcase bores
  2. Crankshaft
  3. Connecting rods
  4. Camshaft
  5. Lubrication system
  6. Flywheel
  7. Pistons and Cylinders
  8. Cylinder head and valves
  9. Cooling
  10. Clutch
  11. Tightening Torques

Volkswagen Type 1 Engines 1600
Tolerances, Wear Limits, and Settings (single-carburetor engines)

Designation

 

New part mm (In.)

Wear limit mm (In.)

Crankcase bores

     
1 - Bores for air bearings --- --- ---
   - Bearings 1, 2 and 3 Diameter 65.00 - 65.02 (2.5590 - 2.5598) 65.03 (2.5602)
   - Bearing 4 Diameter 50.00 - 50.03 (1.9685 - 1.9696) 50.04 (1.9700)
2 - Bore for oil seal/flywheel end Diameter 90.00 - 90.05 (3.5433 - 3.5452) ---
3 - Bores for camshaft bearings Diameter 27.50 - 27.52 (1.0826 - 1.0834) ---
4 - Bore for oil pump housing Diameter 70.00 - 70.03 (2.7559 - 2.7570) ---
5 - Bores for cam followers Diameter 19.00 - 19.02 (.7480 - .7488) 19.05 (.7500)
     

Crankshaft

     
1 - Journal dimensions --- --- ---
   a - Main journals 1, 2 and 3 Diameter 54.97 - 54.99 (2.1641 - 2.1649) ---
   b - Main journal 4 Diameter 39.98 - 40.00 (1.5740 - 1.5748) ---
   c - Connecting rod journals Diameter 54.98 - 55.00 (2.1645 - 2.1653) ---
   d - Three undersizes of 0.25 mm (.010 in.) each      
2 - Crankshaft at No. 2 and No. 4 main journals --- --- ---
     (No. 1 and No. 3 journals on V-blcks) Runout --- 0.02 (.0008)
3 - Crankshaft Imbalance Max. 12 cmg ---
4 - Main baring journal Out-of-round --- 0.03 (.0012)
5 - Connecting rod journal Out-of-round --- 0.03 (.0012)
6 - Crankshaft/main Journals (taking housing preload into aocount): --- --- ---
   a - Bearings 1 and 3 Radial play 0.04 - 0.10 (.0016 - .004) 0.18 (.007)
   b - Steel bearlng 2 Radial play 0.03 - 0.09 (.0012 - .0035) 0.17 (.0067)
   c - Bearing 4 Radial play 0.05 - 0.10 (.0019 - .004) 0.19 (.0074)
7 - Crankshaft/main journal 1 End play 0.07 - 0.13 (.0027 - .005) 0.15 (.006)
8 - Connecting rod journal/connecting rod Radial play 0.02 - 0.07 (.0008 - .0027) 0.15 (.006)
  End play 0.10 - 0.40 (.004 - .016) 0.70 (.027)
     

Connecting rods

     
1 - Weight difference between connecting rods in one engine --- Max. 5 g max. 10 g (during repair)
     Weight of replacement connecting rods --- --- ---
     – Weight (white) brown/white --- 580 - 588 g ---
     + Weight (black) gray/black --- 592 - 600 g ---
2 - Piston pin Diameter 21.996 - 22.00 (.8660 - .8661) ---
3 - Piston pin bush Diameter 22.009 - 22.00 (.8664 - .8667) ---
4 - Piston pin/bush Radial play 0.01 - 0.02 (.0004 - .0008) 0.04 (.0016)
     

Camshaft

     
1 - Bearings 1, 2, and 3 Diameter 24.99 - 25.00 (.9839 - .9843) ---
2 - Measured at center bearing (bearings 1 and 3 on V-Blocks) Runout 0.02 (.0008) 0.04 (.0016)
3 - Camshaft/camshaft bearings (taking housing preload in account) Radial play 0.02 - 0.05 (.0008 - .002) 0.12 (.0047)
     Thrust bearing End play 0.04 - 0.013 (.0016 - .005) 0.16 (.0063)
4 - Camshaft gear Backlash 0.00 - 0.05 (.000 - .002) ---
5 - Cam follower Diameter 18.96 - 18.98 (.7464 - .7472) 18-93 (.7452)
6 - Bore/cam follower Radial play 0.02 - 0.06 (.0008 - .0023) 0.12 (.0047)
7 - Push rod Runout Max. 0.30 (.012) ---
     

Lubrication system

     
1 - Oil pressure (for SAE 30 only) at an oil temperature of 70ºC (158ºF) and 2500 rpm.   Approx 42 psi (3 kg/cm2) 28 psi (2 kg/cm2)
2 - Spring for pressure relief valve through Juli 1969.
     Length loaded: 43.20 mm (1 11/16 in.)
Load 2.5 - 4.2 kg (5.5 - 9.2 lbs.) ---
3 - Spring for pressure relief valve from Aug. 1969
     Length loaded: 44.10 mm (1 ¾ in.)
Load 5.6 - 7.3 kg (12 - 16.0 lbs.) ---
4 - Spring for oil pressure control valve from Aug. 1969 through Jul. 1970
     Length loaded: 20.20 mm (13/16 in.)
Load 2.9 - 3.6 kg (6.3 - 7.9 lbs.) ---
5 - Spring for oil pressure control valve from Aug. 1970
     Length loaded: 20.20 mm (13/16 in.)
Load 3.1 - 3.8 kg (6.3 - 8.4 lbs.) ---
6 - Oil Pressure switch open at Pressure 2.1 - 6.4 psi (0.15 - 0.45 kg/cm2) ---
     

Flywheel

     
1 - Flywheel (measured at center of friction surface)
 
Lateral runuot
Imbalance
Max. 0.30 (.012)
20 cmg
---
---
2 - Shoulder for oil seal Outside diameter 69.9 - 70.1 (2.752 - 2.756) ---
3 - Drive plate, torque converter Imbalance Max. 5 cmg ---
     

Pistons and Cylinders

     
Two oversizes of 0.5 mm (.020 in.) each --- --- ---
1 - Cylinders Out-of-round Max. 0.01 (.0004) ---
2 - Cylinder/piston Clearence 0.04 - 0.06 (.0016 - .0023) 0.20 (.008)
3 - a. Upper piston ring Side clearence 0.07 - 0.10 (.0027 - .0039) 0.12 (.0047)
     b. Lower piston ring Side clearence 0.05 - 0.07 (.0012 - .0027) 0.10 (.004)
4 - OiI scraper ring Side clearence 0.03 - 0.05 (.0012 - .0020) 0.10 (.004)
5 - a. Upper piston ring Gap 0.30 - 0.45 (.012 - .018) 0.90 (.035)
     b. Lower piston ring Gap 0.30 - 0.45 (.012 - .018) 0.90 (.035)
6 - a. Oil scraper piston ring Gap 0.25 - 0.40 (.010 - .016) 0.95 (.037)
7 - Piston weight --- --- ---
     - Weight (brown)
 
---
---
398 - 410 g
402 - 412 g
---
---
     + Weight (gray)
 
---
---
406 - 418 g
410 - 420 g
---
---
8 - Weight differrence between pistons in one engine --- Max. 5 g Max. 10 g
     

Cylinder head and valves

     
1 - Cylinder seating depth in cylinder head --- 13.45 - 13.55 (.5295 - .5334) ---
     a. Rocker arm Inside diameter 18.00 - 18.02 (.7086 - .7094 18.04 (.7102)
     b. Rocker shaft Diameter 17.97 - 17.99 (.7074 - .7082) 17.95 (.7067)
2 - Valve springs Length loaded 31.0 mm (1 7/32 in.) Load 53.2 - 61.2 kg (117 - 135 lb.)
(520 - 600 N)
---
3 - Valve seals --- --- ---
     a. Intake Width new 1.30 - 1.60 (.051 - .063) ---
     b. Exhaust Width new 1.70 - 2.00 (.067 - .0798) ---
     c. Intake Seat angle 45° ---
     d. Exhaust Seat angle 45° ---
     e. Outer seat edge Correction angle 15° ---
     f. Inner seat edge Correction angle 75° ---
4 - Valve guides --- --- ---
     a. Intake Inside diameter 8.00 - 8.02 (.3150 - .3157) 8.06 (.3173)
     b. Exhaust Inside diameter 8.00 - 8.02 (.3150 - .3157) 8.06 (.3173)
5 - Valve stem --- --- ---
     a. Intake Diameter 7.94 - 7.95 (.3126 - .3129) 7.90 (.3110)
     b. Exhaust Diameter 7.92 - 7.94 (.3118 - .3126) 8.88 (.3102)
  Out-of-round 0.01 (.0004) ---
6 - Valve head --- --- ---
         Intake Diameter 35.6 (1.4) ---
         Exhaust Diameter 32.1 (1.26) ---
7 - Valve facing --- --- ---
         Intake Angle 0.44° ---
         Exhaust Angle 0.45° ---
8 - 1972 through 1977 valve clearance (cold) ---   ---
     a. Intake (all engines) Setting 0.15 (.006) ---
     b. Exhaust (1700 dual-carbuieior engines through chassis No.
         213 2210 553 and all fuel-injection engines)
Setting 0.15 (.006) ---
         Exhaust (1800 engines, 1700 engines from Chassis No. 213 2210 554 and earlier 1700
         engines that have been modyfied by the installation of sodium-filled valves)
Setting 0.20 (.008) ---
9 - 1978 valve clearance
 
  Controlled automaticaly by
hydraulic valve lifters
---
10 - Compression pressure --- 114 - 142 psi (8.0 - 10.0 Kg/cm2) 100 psi (7 Kg/cm2)
       Pressure between cylinders --- Max. 28 psi (2 Kg/cm2)
(69 - 93 N/cm2)
---
     

Cooling

     
1 - Thermostat Opennig temperature 65 - 70°C (149 - 158°F) ---
2 - Fan/belt pullley Imbalance Max. 5 cmg ---

     

Clutch

     
1 - Total pressure 1700 (210 mm) 380 - 420 kg (837-925 lbs.) ---
2 - Complete clutch Imbalance Max. 15 cmg ---
3 - Pressure plate Runout --- 0.10 (.004)
4 - Clutch plate [measured at 195 mm (7.677 in.) dia.] Lateral ronout Max. 0.5 (.020) ---
5 - Play at clutch pedal --- 10 - 20 (3/8 - 3/4) ---

Specifications taken from VW Type 2 - © Bentley Official Service Manual - 1968 - 1979
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Tightening Torques (single-carburetor 1600 engine)

Location

Designation

Thread

Quality grade

N-Newton

mkg

ft. lb.

Connecting rods

connecting rod nut

M 9 x 1

8 G

33

3.3

24

Crankcase halves

nut

M 8

5 S

20

2.0

14

Crankcase halves

nut

M 12 x 1.5

35 S 20 K

35

3.5

25

Cylinder head

nut

M 10

35 S 20 KV

32

3.2

23

Rocker shaft to cylinder head

nut

M 8

8 G

25

2.5

18

Heat exchanges on cylinder head

self-locking nut

M 8

20

2.0

14

Muffler clamps

bolls

M 6

10

1.0

7

Intake manifold to cylinder head

nut

M 6

20

2.0

14

Intake manifold 1o cylinder- head

nut

M 8

20

2.0

14

Preheating pipe flange bolls

bolt

M 6

10

1.0

7

Oil pump to crankcase

nut

M 8

20

2.0

14

Oil drain plug

plug

M 14 x 1.5

9 S 20 K

35

3.5

25

Oil strainer to crankcase

nut

M 6

7

0.7

5 (60 in. lb.)

Oil cooler to crankcase

nut

M 6

7

0.7

5 (60 in. lb.)

Oil filler and breather to generator stand

gland nut

55

5.5

40

Flywheel to crankshaft

gland nut

M 28 x 1.5

45 S 20 KN

350

35.0

253

Clutch to flywheel

bolt

M 8x 1.5

8 G

25

2.5

18

Spark plugs

spark plug

M 14 x 1.25

35

3.5

25

Engine to transmission

nut

M 10

30

3.0

22

Engine bearer to crankcase

self-locking bolt

M 8

8 G

26

2.6

18

Engine bearer to crankcase

self-locking bolt

M 10

40

4.0

29

Engine bearer to engine bearer mounting

bolt

M 10

40

4.0

29

Generator pulley

nut

M 12 x 1,5

60

6.0

43

Special nut for fan

nut

M 12 x 1.5

9 S 20 K

60

6.0

43

Crankshaft pulley

bolt

M 20 X 1,5

90 S 20 K

45

4.5

32

Engine bearer mounting to body

self-locking nut

M 8

8 G

25

2.5

18

 
VW Type 2 - Official Service Manual - 1968-1979
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