Contents - Volkspage
Contents - Volkspage
Contents - Volkspage
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2B.1<br />
Chapter 2 Part B:<br />
Engine removal and overhaul procedures<br />
<strong>Contents</strong><br />
Crankshaft - refitting and running clearance check . . . . . . . . . . . . . .10<br />
Crankshaft - removal and inspection . . . . . . . . . . . . . . . . . . . . . . . . .6<br />
Cylinder block/crankcase - cleaning and inspection . . . . . . . . . . . . . .7<br />
Cylinder head - dismantling, cleaning, inspection and assembly . . . .4<br />
Engine overhaul - preliminary information . . . . . . . . . . . . . . . . . . . . . .3<br />
Engine overhaul - reassembly sequence . . . . . . . . . . . . . . . . . . . . . .9<br />
Engine - initial start-up after overhaul and reassembly . . . . . . . . . . .13<br />
Engine and transmission - removal, separation and refitting . . . . . . . .2<br />
Degrees of difficulty<br />
Engine and transmission removal - preparation and precautions . . . .1<br />
Flywheel - removal, inspection and refitting . . . . . . . . .see Chapter 2A<br />
Main and big-end bearings - inspection and selection . . . . . . . . , . . .8<br />
Piston and connecting rod assemblies - refitting and big-end running<br />
clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...12<br />
Pistons and connecting rods - removal and inspection . . . . . . . . . . . 5<br />
Pistons and piston rings - assembly . . . . . . . . . . . . , . . . . . . . . . . . .11<br />
Specifications<br />
Engine designation codes<br />
See Chapter 2A<br />
Crankshaft<br />
Main journal diameter (standard) ..............................<br />
Undersizes ...............................................<br />
Crankpin journal diameter (standard) ...........................<br />
Undersizes ...............................................<br />
Endfloat .................................................<br />
Main bearing running clearance ..............................<br />
Crankpin running clearance ..................................<br />
Connecting rods<br />
Endfloat on crankpin .......................................<br />
Pistons<br />
Diameter:<br />
Standard ..............................................<br />
Oversizes ..............................................<br />
Piston rings<br />
End gap (15.0 mm from bottom of cylinder):<br />
Compression rings .......................................<br />
Oil scraper ring ..........................................<br />
Clearance in groove ........................................<br />
Cylinder head<br />
Distortion (max) ...........................................<br />
Minimum height for machining ...............................<br />
Minimum distance between tops of valve guides and<br />
upper surface of cylinder head:<br />
Exhaust ..............................................<br />
Inlet .................................................<br />
Camshaft<br />
Run-out(max) ............................................<br />
Endfloat .................................................<br />
53.96 to 53.97mm<br />
-0.25 mm - 0.5 mm, -0.75 mm<br />
41.96 to 41.97 mm<br />
-0.25 mm, -0.5 mm, -0.75 mm<br />
0.07 to 0.20 mm<br />
0.03 to 0.17 mm<br />
0.02 to 0.095 mm<br />
0.05 to 0.40 mm<br />
74.985<br />
75.235, 75.485, 75.735<br />
0.30 to 1 .0 mm<br />
0.25 to 1 .0 mm<br />
0.02 to 0.15 mm<br />
0.1 mm<br />
135.6 mm<br />
36.1 mm<br />
35.8 mm<br />
0.01 mm<br />
0.15 mm
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