NOTE: For cylinder head and piston & cylinder overhaul see related article.

Crankcase Disassembly

1. Remove engine from vehicle and place on engine stand. Remove manifolds, cylinder heads, pistons and cylinder sleeves. Note directional arrows on carrier, and remove engine carrier assembly.
2. Mark pressure plate position for installation reference, and remove pressure plate and clutch disc. Remove flywheel or drive plate. Remove crankcase breather tower. Remove distributor assembly. Index distributor drive shaft gear to ensure installation to exact position.
3. Remove water pump assembly. Remove thermostat housing. Remove oil filter and cooler. Pry out front and rear crankshaft seals.
4. Remove oil filler tube. Remove oil pump cover and gears. Remove oil pump housing and gasket. Remove lifters. Keep lifters in a marked order for installation. Remove nuts retaining crankcase halves together.
5. Separate crankcase halves. Use a rubber mallet if necessary. DO NOT use pry bars or levers between crankcase halves, oil leaks will occur. Lift camshaft from crankcase. Remove crankshaft and connecting rods as an assembly. Remove distributor drive shaft gear and shims.
6. Remove bearings from crankcase halves. Remove main bearing locating dowels. Remove camshaft plug.

Crankshaft, Rod & Main Bearings

1. Remove crankshaft and rods assembly. Mark rod and rod caps with matching cylinder number. Note position of rod to ensure installation to original position. Remove and discard rod cap nuts nuts. Remove rod and cap.
2. Note position of rod bearing and remove bearing. Keep rod bearing with rod from which it was removed. Repeat procedure for remaining rods to be removed. If replacing rods, they must be replaced as a complete set of 4.
3. Note color mark(s) on crankshaft. Main bearings must match crankshaft color. Remove Woodruff key and snap ring from crankshaft. Place assembly in press. Using Plate (VW 402), press off crankshaft timing gear and distributor drive gear.
4. Check side clearance with rods installed on crankshaft. Using a feeler gauge, measure between rod and crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS TABLE under ENGINE SPECIFICATIONS at end of article. Check crankshaft journals for wear and damage. Blow out oil holes with compressed air. Replace as necessary.
5. Place crankshaft in vise. Heat crankshaft timing gear and distributor drive gear to 175°F (80° C). Oil main bearing, and place bearing on crankshaft with dowel locating hole facing crankshaft web.
6. Place heated gears and spacer on crankshaft. Ensure timing marks (2 dots) on crankshaft gear are facing out. Install snap ring. Oil main bearing and install with groove toward oil thrust ring.
7. Install oil thrust ring and Woodruff key. Install connecting rod bearings in rods and caps, with tangs engaging notches. Install connecting rods to proper cylinder, with forged mark on rod facing up. Install and snugly tighten NEW rod nuts and tighten snug.
8. Tap both sides of rod lightly to keep bearing shells from being pinched. Tighten rod nuts to specification. See TORQUE SPECIFICATIONS TABLE at end of article.

Crankcase Assembly

1. Clean all sealant from bolts, nuts and washers. Clean old sealant from crankcase. Blow out all oil galleys with compressed air. Ensure studs are tight.
2. Ensure bearing locating dowels fit snugly in crankcase. Install main bearing and camshaft bearings in crankcases. Lubricate bearings with engine oil. Lay crankshaft and connecting rods into left half of crankcase. Properly align main bearings and locating dowels.
3. Install camshaft with "O" mark between marks on crankshaft gear. Check backlash of timing gears. Rotate crankshaft backward. If camshaft lifts out of bearing, install a smaller camshaft gear. Size of camshaft gear is marked on inner side of gear. Smaller size camshaft gears are available to adjust backlash. Coat edge of camshaft plug with sealant, and install plug.
4. Install rear thrust washer with tab on thrust washer toward main bearing and separating line of crankcase. Ensure projection on main bearing fits in notches in crankcase. Oil holes must be in left half of crankcase.
5. Apply a thin layer of Sealant (AMV 188 000 02) to mating surfaces of both crankcase halves. Place right half of crankcase over studs, and compress crankcase halves together. Coat both sides of washers and face of cap nuts with Sealant (D3).
6. Tighten 8-mm nut above and behind No. 1 exhaust lifter bore first. Tighten all 10-mm nuts and then all remaining 8-mm nuts. Place No. 1 cylinder on TDC. Install distributor drive gear. Ensure drive gear is in exact position as marked at removal.
7. To complete installation, reverse removal procedure. Tighten all bolts/nuts to specification. Fill fluid levels. Bleed cooling system.

   NOTE: Use only Sealant (AMV 188 000 02) on crankcase half mating surfaces.

CYLINDER BLOCK SPECIFICATIONS

END PLAY SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

TORQUE SPECIFICATIONS