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 to 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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