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Home / Typ 4 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 4/2 Engines 1700, 1800 and 2000
Tolerances, Wear Limits, and Settings (dual-carburetor and fuel injection engines)

Designation

 

New part mm (In.)

Wear limit mm (In.)

Crankcase bores

      
1 - Bores for air bearings --- --- ---
   - Bearings 1, 2 and 3 Diameter 70.00 - 70.02 (2.7559 - 2.7567) 70.03 (2.7570)
   - Bearing 4 Diameter 50.00 - 50.03 (1.9685 - 1.9696) 50.04 (1.9700)
2 - Bore for oil seal/flywheel end Diameter 95.00 - 95.05 (3.7401 - 3.7421) ---
3 - Bore for oil seal/fan end Diameter 62.00 - 62.05 (2.4409 - 2.4429) ---
4 - Bores for camshaft bearings Diameter 27.50 - 27.52 (1.0826 - 1.0834) ---
5 - Bore for oil pump housing Diameter 70.00 - 70.03 (2.7559 - 2.7570) ---
6 - Bores for cam followers Diameter 24.00 - 24.02 (.9448 - .9456) 24.05 (.9468)
     

Crankshaft

      
3 undersizes of 0.25 mm (.010 in.) each --- --- ---
1 - Crankshalt --- --- ---
   a - Main journals 1, 2 and 3 Diameter 59.97 - 59.99 (2.3610 - 2.3618) ---
   b - Main journal 4 Diameter 39.98 - 40.00 (1.5740 - 1.5748) ---
   c - Connecting rod journals - 1.7L (1972-1975)  Diameter 54.98 - 55.00 (2.1645 - 2.1653) ---
   d - Connecting rod journals - 1.8L (1976) Diameter 49.98 - 50.00 (1.9677 - 1.9685) ---
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 0.05 - 0.10 (.002 - .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 (.0275)
     

Connecting rods

      
1 - Weight difference between connecting rods in one engine --- Max. 6 g max. 10 g (during repair)
     Weight of replacement connecting rods --- --- ---
     – Weight (white) brown/white --- 746 - 752 g ---
     + Weight (black) gray/black --- 769 - 775 g ---
2 - Piston pin Diameter 23.996 - 24.00 (.9445 - .9448) ---
3 - Piston pin bush Diameter 24.015 - 24.024 (.9454 - .9457) ---
4 - Piston pin/bush Radial play 0.01 - 0.03 (.0004 - .0012) 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 23.96 - 23.98 (.9433 - .9440) 23.33 (.9421)
6 - Bore/cam follower Radial play 0.02 - 0.06 (.0008 - .0023) 0.12 (.0047)
7 - Push rod Runout Max. 0.3 (.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
     Length loaded: 44.1 mm (1.73 in.)		 Load --- ---
3 - Spring for oil pressure relief valve
     Length loaded: 39.0 mm (1.54 in.)		 Load 6.8 - 8.8 kg (15 - 19½ lbs.) ---
4 - Spring for oil pressure control valve
     Length Ioaded: 20.2 mm (./95 in.)		 Load --- ---
5 - Spring for oil pressure control valve
     Length loaded: 26.0 mm (1.02 in.)		 Load 1.7 - 2.0 (3¾ - 4½ lbs.) ---
6 - Pressure switch open at Pressure 2.1 - 6.4 psi (.15 - .45 kg/cm2) ---
     

Flywheel

      
1 - Flywheel (measured at center of friction surface)
 		 Lateral runuot
Imbalance		 Max. 0.40 (.016)
20 cmg		 ---
---
2 - Shoulder for oil seal Outside diameter 74.9 - 75.1 (2.948 - 2.956) ---
3 - Drive plate Imbalance Max. 5 cmg ---
     

Pistons and Cylinders

      
2 oversizes of 0.5 mm (.020 in.) each --- --- ---
1 - Cylinders Out-of-round Max. 0.01 (.0004) ---
2 - Cylinder/piston ring Clearence 0.04 - 0.06 (.0016 - .0023) 0.20 (.008)
3 - a. Upper piston ring Side clearence 0.06 - 0.09 (.0023 - .0035) 0.12 (.0047)
     b. Lower piston ring Side clearence 0.04 - 0.07 (.0016 - .0027) 0.10 (.004)
4 - OiI scraper ring Side clearence 0.02 - 0.05 (.0008 - .0020) 0.10 (.004)
5 - a. Upper piston ring Gap 0.35 - 0.55 (.014 - .022) 0.90 (.035)
     b. Lower piston ring Gap 0.30 - 0.55 (.012 - .022) 0.90 (.035)
6 - a. Oil scraper piston ring Gap 0.25 - 0.40 (.010 - .016) 0.95 (.037)
7 - Piston weight --- --- ---
     - Weight (brown)
 		 ---
---		 496 - 504 g
456 - 464 g		 ---
---
     + Weight (gray)
 		 ---
---		 504 - 512 g
464 - 472 g		 ---
---
8 - Weight differrence between pistons in one engine --- Max. 4 g Max. 10 g
     

Cylinder head and valves

      
1 - Cylinder seating depth in cylinder head --- 5.4 - 6.5 (.2126 - .2559) ---
     a. Rocker arm Inside diameter 20.00 - 20.02 (.7874 - .7882 20.04 (.7890)
     b. Rocker shaft Diameter 19.95 - 19.97 (.7854 - .7862) 19.93 (.7846)
2 - Valve springs Length loaded 29.0 mm (1.14 in.) Load 76.5 - 84.5 kg (168 - 186 lb.)
(750 - 828 N)		  
2 - Valve springs Length loaded 29.0 mm (1.14 in.) Load 76.5 - 84.5 kg (168 - 186 lb.)
(750 - 828 N)		 ---
3 - Valve seals --- --- ---
     a. Intake Width new 1.8 - 2.2 (.070 - .086) ---
     b. Exhaust Width new 2.0 - 2.5 (.078 - .098) ---
     c. Intake Repair width 1.3 - 1.6 (.051 - .063) ---
     d. Exhaust Repair width 1.7 - 2.0 (.067 - .079) ---
     e. Intake Seat angle 30° ---
     f. Exhaust Seat angle 45° ---
     g. Outer seat edge Correction angle 16° ---
     h. 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 8.98 - 8.99 (.3535 - .3539) 9.06 (.3566)
5 - Valve stem --- --- ---
     a. Intake Diameter 7.94 - 7.95 (.3126 - .3129) 7.90 (.3110)
     b. Exhaust Diameter 8.91 - 8.92 (.3507 - .3511) 8.87 (.3492)
  Out-of-round 0.01 (.0004) ---
6 - Valve head --- --- ---
     a. Intake (1700 dual-carburetor engine 411/412) Diameter 37.50 (1.476) ---
         Intake (1700 dual-carburetor engine) Diameter 39.30 (1.5472)  
         Intake (1800 dual-carburetor engine)  Diameter 41.00 (1.1642) ---
         Intake (1700 fuel-injection engine 411/412 D-Jetronic) Diameter 39.00 (1.536) ---
         Intake (1800 fuel-injection engine L-Jetronic) Diameter 39.30 (1.5472)  
         Intake (2000 fuel-injection engine L-Jetronic) Diameter 37.50 (1.4764) ---
     b. Exhaust (1700 dual-carburetor engine) Diameter 33.00 (1.2992) ---
         Exhaust (1800 dual-carburetor engine)  Diameter 34.00 (1.3386) ---
         Exhaust (1800 fuel-injection engine L-Jetronic) Diameter 33.00 (1.2992) ---
         Exhaust (2000 fuel-injection engine L-Jetronic) Diameter 33.00 (1.2992) ---
7 - Valve guide/valve stem: --- --- ---
     a. Intake Rock 0.45 (.018) 0.90 (.035)
     b. Exhaust Rock 0.35 (.014) 1.20 (.047)
8 - 1972 through 1977 valve clearance (cold) ---   ---
     a. Intake (all engines) Setting 0.15 (.006) ---
     b. Exhaust (1700 dual-carburetor engines through chassis No.
         213 2210 553 and all fuel-injection engines)		 Setting 0.15 (.006) ---
     b. 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 (2000 fuel-injection engine)
 		   Controlled automaticaly by
hydraulic valve lifters		 ---
10 - Compression ---    
       a. 1700 engine Pressure 100 - 135 psi (7.0 - 9.5 Kg/cm2) 85 psi (6.0 Kg/cm2)
       b. 1800 and 2000 engine Pressure 85 - 135 psi (6.0 - 9.5 Kg/cm2) 71 psi (5.0 Kg/cm2)
       c. Pressure difference between cylinders --- Max. 28 psi (2 Kg/cm2) ---
     

Cooling

      
1 - Thermostat (through Sept. 1972) Opennig temperature 65 - 70°C (149 - 158°F) ---
     Thermostat (from Oct. 1972) Opennig temperature 85 - 90°C (185 - 194°F) ---
2 - Fan/belt pullley Imbalance Max. 5 cmg ---

     

Clutch

      
1 - Total pressure 1700 (210 mm) 380 - 440 kg (837-970 lbs.) ---
  1800 (215 mm) 420 - 485 kg (924 - 1067 ibs.) ---
  2000 (228 mm) 460 - 520 kg (1014 - 1146 ibs.) ---
2 - Complete clutch Imbalance Max. 15 cmg ---
3 - Pressure plate Runout --- 0.10 (.004)
4 - Clutch plate Lateral ronout Max. 0.5 (.020) ---
5 - Clutch pedal --- --- ---
     a. Through chassis No. 213 2129 106 Freeplay 10 - 20 (3/8 - ¾) ---
     b. Through chassis No. 213 2129 107 Freeplay 15 - 25 (5/8 - 1) ---


Specifications taken from VW Type 2 - © Bentley Official Service Manual - 1968 - 1979

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Tightening Torques (dual-carburetor and fuel injection 1700, 1800, and 2000 engines)

Location

Designation

Thread

Quality grade

N-Newton

mkg

ft. lb.

Connecting rods

connecting rod nut

M 9 x 1

41 Cr 4

33

3.3

24

Crankcase halves

nut

M 8

6 G

20

2.0

14

Crankcase halves

sealing nut

M 10 X 1.25

35 S 20 KV

35

3.5

25

Cylinder head

nut

M 10

35 3 20 KV

32

3.2

23

Rocker shaft to cylinder head

nut

M 7

6 G

14

1.4

10

Heat exchangers to cylinder head

self-locking nut

M8

—

22

2.2

16

Muffler to heat exchangers

self-locking nut

M 8

—

20

2.0

14

Oil drain plug

plug

M 12 x 1.5

9 S 20 K

22

2.2

16

Oil pan cover to crankcase

sealing nut

M 8

9 S 20 K

13

1.3

9

Drive plate to crankshaft

socket head screw

M 12 x 1.5

10 K

90

9

65

Hub to crankshaft

self-locking bolt

M 8

SAE 1022

32

3.2

23

Fan to hub

socket head screw

M 8

—

20

2.0

14

Extension shaft w.th pulley to fan

bolt

M 8

—

20

2.0

14

Spark plugs

spark plug

M 14 x 1.25

—

30

3.0

22

Engine to transmission

nut

M  10

—

30

3.0

22

Engine bearer support to crankcase

self-locking bolt

M 8

—

30

3.0

22

Bonded rubber mourning to support/engine bearer

self-locking nut

M 8

—

20

2.0

14

Engine bearer to engine bearer mounting.

self-locking nut

M 8

—

20

2.0

14

Engine bearer mounting to body

self-locking nut

M 8

—

20

2.0

14

Oil pump to crankcase

nut

M 8

—

20

2.0

14

Oil cooler to crankcase

nut

M 6

—

7

0.7

5 (60 in. lb.)

Flywheel to crankshaft

sett-locking bolt

M 12 x 1.5

22 Cr 4

110

11.0

80

Clutch to flywheel

bolt

M 8 x 20

8 G

25

2.5

18

Torque converter to driveplate

bolt

M 8

8 G

20

2.0

14

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