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Type II Van Engine Specs (Specifications)
1965-1971 Carbureted

ll. Tolerances, Wear Limits, and Settings

Designation New Parts on Installation Wear Limit mm (in.)
A. Crankcase bores
1. Bores for main bearings
   a. Bearings 1, 2, and 3 diameter 65.00-65.02 (2.5591-2.5598) 65.03 (2.5602)
   b. Bearing 4 diameter 50.00-50.03 (1.9685-1.9697) 50.04 (1.9701)
2. Bore for oil seal/flywheel end diameter 90.00-90.05 (3.5433-3.5453)
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 (2.7559-2:7571)
5. Bores for cam followers diameter 19.00-19.02 (.7480-.7488) 19.05 (.7500)

B. Crankshaft
1. Journal dimensions

a. Main journals 1, 2, and 3 diameter 5~.97-54.99-'(2.1641-2.11 649) -
b. Main journal 4 ....... diameter 39.98-40.00 (1.5740-1.5748) -
c. Connecting rod journals ...... .................. diameter 54.98-55.00 (2.1646-2.1654) -
d. Three undersizes of 0.25 mm (.010 in.) each
2. Crankshaft at No. 2 and 4 main journals (No. 1 and 3 journals on V-blocks) runout 0.03 (~001 2)

3. Crankshaft imbalance max. 12 cmg
4. Main bearing journal out-of-round - 0.03 (.0012)
5. Connecting rod journal .................... out-of-round - 0. 03 (100 12)
6. Crankshaft/main journals (taking housing preload into account):

a. Bearings 1 and 3. " . I radial play 0.04-0.10 (.0016-.004) 0.18(.007)
b. Steel bearing 2 ..... radial play 0.03-0.09 (.001-.0035) O~. 17 (.0067)
c. Bearing 4 radial play 0.05-0.10 (.002-.004) 0.19 (.0075)

7. Crankshaft/main journal. 1 end play 0.07-0.13 (.0027-.0051) 0.15(.006)
8. Connecting rod journal /connecting rod .......... radial play 0.02-0.07 (.0008-.0028)~. 0 ' 15(.006) end play 0.10-0.40(.004-.016) 0.70(.028)

C. Connecting rods
1. Weight difference between connecting rods in one engine max. 5 g max. 10 g

Weight of replacement connecting rods

Weight (brown)

........ ............ 580-588 g

+ Weight (gray) 592-600 g

2. Piston pin ........... ....... diameter 21.996-22.00 (.8658-.8661)

3. Piston pin bush diameter 22.009-22.017 (.8665-.8668)

4. Piston pin/pin bush radial play 0.01 -0.02 (.0004-.0008) 0.04 (.0016)

D. 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 into account)
radial play 0.02-0.05 (.0008-.002) 0.12 (.0047)
Thrust bearing end play 0.04-0.13 (.0016-.0051) 0.16 (.0063)

4. Camshaft gear ............ backlash 0.00-0.05 (.000-.002) -

5. Cam follower diameter 18.96-18.98 (.74M 7472) 18.93 (.7453)

6. Bore/cam follower radial play 0.02-0.06 (.0008-.0024) 0.12 (.0047)

7. Pushrod runout max. 0.30 (.012) -

E. Lubrication
1. Oil pressure (for SAE 30 only) at an oil temperature of 70'C (158'F) and 2500 rpm .................................. min. 28 psi (2 kg/cm2)
2. Spring for pressure Relief valve, loaded length 44.1 mm (1.73 in.) load 5.6-7.3 kg (12.3-16.1 lb.)
3. Spring for oil pressure control valve, loaded length 20.2 mm (0.79 in.) load 3.1-3.8 kg (6.8-8.4 lb.)
4. Oil pressure switch opens at ................ ... pressure 2.1-6.4 psi (0.15-0.45 kg/CM2)

F. Flywheel
1 . Flywheel (measured at center of friction surface). . lateral runout max, 0.30 (.012)

imbalance max. 20 cmg

2. Shoulder for oil seal outside diameter 69.9-70.1 (2.752-2.760)
3. Drive plate ................... imbalance max. 5 cmg

Cylinders and pistons
Two oversizes of 0.5 mm (.020 in.) each

1. Cylinders .......... out-of-round max. 0.01 (.0004)

6 1976 VWOA

ENGINE 59

Ill. Tolerances, Wear Limits, and Settings (continued)

Now Parts-oiW-4ftstallation Wear Limit

Designation mm mm (in.)

2. Cylinder/piston clearance 0.04-0.06 (*d)ft-~'0624) 0.20(.008)

3. Ring side clearance . 111111111 Q.07-0.10 (.0028-.0039) 0.12 (.0047)

a. Upper pi t -TZS-~ Q

-0. Lower p - . .002

c. Oil scraper ring 0.03-0.05 (.0012-.0020) 0.10(.004)

4. Ring gap

a. _ppper piston ring 0.30-0.45 (.012-.018) 0.90(.035)

5-Lo 17-.018) 0.90 (.035)

C. Oil scraper ring 0.25-0.40 (.010-.016) 0.95(.037)

5. Piston weight

I - Weijht (brown) 398-410 g

r'*'Q.Xight (gray) ................. 406-418 g

V4ight (brown) from August 1971 402-412 g

+ Weight (gray) from August 1971 410-420 g

6. Weight difference between pistons in one engine max. 5 g max. 10 g

H. Cylinder head and valves

1 . Cylinder seating depth in cylinder head 13,45-13.55 (.530-.533) -

2. Rocker arm inside diameter 18.00-18.02 (.7087-.7095) 18.04 (.7102)

3. Rocker shaft diameter 17.97-17.99 (.7075-.7083) 17.95 (.7067)-

4. Valve spring tension at a loaded length of 31.0 mm (1.22 inches) load 53.2-61.2 kg (117.3-134.9 lb.) -

5. Valve seats

a. Intake width 1.3-1.6 (.051-.063) -

b. Exhaust width 1.70-2.00 (.067-.079) -

c. Intake seat angle 45* -

d. Exhaust . : seat angle 45* - .

e. Outer correction angle - .15*

f. Inner correction angle 75* -

6. Valve guides

a. Intake(* inside diameter 8.00-8.02 (.3150-.3158) 8.06 (.3173)

b. Exhaust (carburetor engines) inside diameter 8.00-8.02 (.3150-.3158) 8.06 (.3173)

c. Exhaust (fuel injection engines) r. inside diameter 9.00-9.02 (.3543-.3551) 9.06 (.3507)

7. Valve stem

a. Intake diameter 7.94-7.95 (.3126-.3130) 7.90 (.3110)

b. Exhaust (carburetor engines) diameter 7.91-7.92 (.3114-.3118) 7.88 (.3102)

c. Exhaust (fuel injection engines) diameter 8.91-8.92 (.3508-.3512) 8.88 (.3496)

out-of-round 0.01 (.0004)

8. Valve head

a. Intake .......... ........... .......... diameter 35.6(l.40)

b. Exhaust (obrburetor engines) diameter 32.1 (1.26)

c. Exhaust (fuel injection engines) diameter 30.1 (1.19)

9. Valve facing

a. Intake angle 44o

b. Exhaust angle 45*

10. Valve guide/valve stem (intake and exhaust) rock 0.23-0.27 (.009-.011) 0.80(.032)

11. Valve clearance (cold)

a. Intake setting 0.15(.006)

b. Exhaust setting 0.15(.006) -

12. Compression
a. Compression pressure from Aug. 1967 114-142 psi (8.0-10.0 kg/CM2) 100 psi (7 kg/CM2) from Aug. 1971 107-135 psi (7.5-9.5 kg/CM2) 85 psi (6 kg/CM2)

b. Pressure difference between cylinders .1 max. 28 psi (2 kg/CM2) -

1. Cooling

1. Thermostat opening temperature 65-70-C (149-158-F)

2. Fan and pulley out Of balance max. 5 cmg

J. Clutch
1. Total pressure 380-420 kg (838-926 lb.)
2. Complete clutch out of balance max. 15 cmg
3. Pressure plate runout 0.10(.004)
4. Clutch plate (measured at 195 mm [7.677 in.] dia.) lateral runout max. 0.50 (.020)
5. Play at clutch pedal 10-20 (%-3/4)

IV. Basic Tune-up Specifications
                                    !!!   WARNING   !!!             
The specs below are the original ones for these cars when they were new and had all the original emission devices on them. It would be very impractical to set ignition timing to these numbers today. The car might be near undrivable and gutless. Most air-cooled motors should be set close to 7 degrees initial at idle and should advance to about 30 degrees total when accelerated to 2500 RPM. Motors with higher than standard compression might require retarding the timing slightly. Idle speed should be about 950 RPM
 

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