Volkswagen Air-Cooled 1970-1981 Repair Guide




On the Type 1 and 2/1600, the crankshaft pulley can be removed while the engine is still in the car. However, in this instance it is necessary for the rear cover plate of the engine to be removed. Remove the cover plate after taking out the screws in the cover plate below the crankshaft pulley. Remove the fan belt and the crankshaft pulley securing screw. Using a puller, remove the crankshaft pulley. The crankshaft pulley should be checked for proper seating and belt contact. The oil return thread should be cleaned and lubricated with oil. The crankshaft pulley should be installed in the reverse sequence. Check for oil leaks after installing the pulley.

On the Type 3, the crankshaft pulley can be removed only when the engine is out of the car and the muffler, generator, and cooling air intake housing are removed. After these parts have been removed, take out the plastic cap in the pulley. Remove the crankshaft pulley retaining bolt and remove the pulley.

Type 4 and Type 2/1700, 2/1800 and 2/2000, removal is the same as the Type 3. However, the pulley is secured by three socket head screws and a self locking nut.

Installation for Type 2/1700, 2/1800, 2/2000, 3 and 4 engines is the reverse of removal. When installing, use a new paper gasket between the fan and the crankshaft pulley. If shims are used, do not forget them. Don't use more than two shims. When inserting the pulley, make sure that the pin engages the hole in the fan. Ensure that the clearance between the generator belt and the intake housing is at least 4mm and that the belt is parallel to the housing.

Flywheel See Figures 1, and 2

Click image to see an enlarged view

Fig. Fig. 1: Because of the large amount of torque holding the flywheel gland nut onto the crankshaft, a removal and installation tool can be fabricated from a 4 ft. length of angle iron stock

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Fig. Fig. 2: Cutaway view of the crankshaft-to-flywheel gland nutthe gland nut also houses a set of needle bearings

In order to remove the flywheel, the crankshaft will have to be prevented from turning. This may be accomplished on Type 1, 2/1600 and Type 3 models by using a 3 or 4 foot length of angle iron or thick stock sheet steel, such as an old fence post. Drill out two holes in the metal bar that correspond to two of the pressure plate retaining bolt holes. The metal bar is installed as per the accompanying illustration.TYPES 1, 2/1600 AND 3

The flywheel is attached to the crankshaft with a gland nut and is located by four dowel pins. An oil seal is recessed in the crankcase casting at No. 1 main bearing. A needle bearing, which supports the m