Volkswagen Type II Transporter 1200 Series Install guide

Type II
Trans~2!:~~o~6oo
SHOP MANUAL
------- .
~-I(, ---t.lt-----2},g> ___ ___.,.
L
~
'--------"'"' _______ ____..
I )\
1 I~
i I J
~
Ill "
'\ ......
l I
I I
I I
I I
. -L-----1
L_~~~~~JJ

PAGE 2

Volkswagen
Transporters
Series 1200 1500 1600
With Specifications,
Repair and Maintenance Data

PAGE 4

ENGINE................................................ 7
COOLING
AND EXHAUST
SYSTEM ............................................ 48
FUEL SYSTEM .................................. 55
CLUTCH ............................................... 74
TRANSMISSION AND REAR
AXLE ................................................... 82
STEERING ..................... , .................... 147
FRONT AXLE AND
SUSPENSION ................................. 161
REAR SUSPENSION ...................... 174
BRAKES ............................................... 179
ELECTRICAL SYSTEM .................. 194 .
BODY ..................................................... 224.
WHEELS AND TIRES ...................... 241
LUBRICATION AND
MAINTENANCE. ............................ 246

PAGE 6

ENGINE
SPECU'ICATIONS
Type ....................... .
Bore
....................... .
Stroke
.... ~ ................. .
·Capacity
..................... .
Bhp (max) ................... .
•200 ENGINES
36 bhp (Early)
3.03"
2.52"
72.74
cu in
36 at 3700 rpm
36 bhp (Late)
3.03"
2.52"
72.74
cu in
36 at 3700 rpm
40bhp
3.03"
2.52"
72.72 cu
in
Maximum torque ............... .
Compression ratio
.............. .
56 ft/lb at 2000 rpm
6.6:1
58 ft/lb at 2400 rpm
6.6:1
4Ls at 3900 rpm
65 ft/lb at 2400 rpm
7.0:1
Ignition firing point
............. . 7.5° btdc
CRANKSHAFT
Main bearing type:
Early 36 bhp Nos 1, 3, 4
No2 ................. .
Late 36 bhp Nos
1, 2, 3 ....... .
No4 .................. .
Early 40 bhp
.............. .
Aluminium alloy
bushes
Aluminium alloy
shells
Steel-backed,
lead bronze
shells
Aluminium alloy
bush
As for late
36 bhp
Late 40 bhp Nos 1, 3, 4 . . . . . . . . Aluminium alloy
bushes
No 2 . . . . . . . . . . . . . . . . . . Aluminium alloy
shells
Crankcase bore for crankshaft bearings:
Nos
1, 2, 3 bearings ..... ·. . . 2.5591'7 -25598"
Except up to Engine No 3520332 2.3622" -2.3630"
No 4 all 1200engines .. ; . . . . 1.9685" -1.9696"
*Crankshaft end float
( t N 1 b . ) .0027"
-.005"
a o eanng ......... .
Crankshaft journal nominal diameter:
Early 36 bhp Nos 1, 2, 3 and
connecting rod journals . . . . . . 1.9685"
All other engines . . . . . . . . . . . 2.1653"
All engines, No 4 main bearing
journal . . . . . . . . . . . . . . . . . 1.5748"
~~<'No l main bearing is adjacent to the flywheel.
7.5° btdc 10° btdc
PISTONS
AND RINGS
Piston
io cylinder clearance .....
Piston ring side clearance:
Upper compression ........ .
Except early 36 bhp
....... .
Lower compression
....... .
Oil scraper ............. .
Piston ring
gap:
Compression . . . . . . . . . ... .
Oil scraper ............. .
Weight
in variation between
pistons
in one engine .......... .
.0018" ± .0002"
.0031" ±.0004"
.0024"± .0004"
.0024" ± .0004"
.001"± .001"
.000"
.015" ± .003"
.013" ±.003"
18 oz (max)
CONNECTING RODS
Big-end bearing clearance:
Early 36 bhp engine
....... .
Later engines
............ .
Big end bearing end float:
Early 36 bhp engine
....... .
Later engines
............ .
Gudgeon pin clearance
in bush:
Early 36 bhp engine . .
..... .
Later engines
............. .
Weight variation between
connecting rods
............ ~
.0008" -.0024"
.0008" -.003"
.0067" -.016"
.004" -.016"
.0004" -.001"
.0004" -.0008"
.18 oz (new)
-.36 oz (wear
limit when
repairing)
CAMSHAFT
Bearing bore for shaft
............ .
Backlash between gears
........... .
Beai:ing clearance . . . . . . . . . . . . . . . .
End play
..... ·· ................ .
.9456"
-.9458"
.000" -.002"
.0008"
-.0021"
.0008" -.0027"
7
.9850" -.9857"
.000" -.002"
.0008"
-.0021 "
.0016"
-.0051"
.9850" -.9857"
.000" -.002"
.0008" -.0021"
.0016" -.0051"

2-Engine
Valve head diameter:
Inlet
..................... .
Exhaust ................... .
Valve stem diameter:
Inlet ..................... .
Exhaust
......... .
Guide inner diameter:
Inlet
..................... .
Exhaust ................... .
Valve seat width:
Inlet
..................... .
Exhaust ................... .
Valve clearance (cold):
Inlet
..................... .
VALVES
36 bhp (Early)
1.18"
1.1 02"
.2736" -.2739"
.2732" -.2736"
.2759" -.2763,
.2763" ~.2771,
.05" -.06"
.07" -.08"
.004"
Exhaust . . . . . . . . . . . . . . . . . . . . .004"
*Up to Engine No 9205699 or without relevant sticker:
Inlet
..................... .
Exhaust ................... .
Valve timing (clearance at .040"):
Inletopens
................. .
Inlet closes
................. .
Exhaust closes ............... .
Exhaust opens
............... .
Later model 40 Bhp:
Inlet opens
................. .
Inlet closes
................. .
Exhaust opens
............... .
Exhaust closes . . . . . . . . . . . .
... .
Valve springs pressure:
2.5° btdc
37.5° abdc
2.5° atdc
37.5° bbdc
6° btdc
35°30'abdc
42°30'bbdc
Loaded length 1.102" . . . . . . . . . . . 73.5 ±3.7lbs
Loaded length 1.314"
.......... .
*Sticker placed on fan housing.
36 bhp (Late)
1.239"
1.181,
.3126" -.3130"
.3114" -.3118"
.3150" -.3157''
.3150" -.3157''
.05" -.06"
.07'' -.08"
.004"
.004"
.008"
.0 12"
2°atdc
24° abdc
9° btdc
32° bbdc
97 ±6.6lbs
ROCKERS AND TAPPETS
Rocker arm inside diameter ........ .
Rocker shaft diameter
............ .
Crankcase bore diameter
.......... .
Tappet diameter
................ .
.6294"
-.6306"
.6286" -.6290"
.5905" -.5912"
.5892" -.5399"
.7086" -.7093"
.7073" -.7077"
.7480" -.7488"
.7464" -.7475"
LUBRICATION SYSTEM
Oil pressure:
With engine hot 3000 rpm . . . . . . . . 28 psi
Pressure relief valve:
Spring free length . . . . . . . . . . . . . . 2.05" -2.08"
Loaded length .945" ............. .
Relief
valve opens at. . . . . . . . . . . . . . . 4.2 .:....8.5 psi
28 psi
17lbs
2.1 -6.4 psi
8
40bhp
1.299"
1.181,
.3126" -.3130"
.3114" -.3118"
.3150" -.3157''
.3150" -.3157''
.05" -.06" '
.07''
-.08"
.004"
.004"
.008"
.012"
4° btdc
32° abdc
1° atdc
41° bbdc
97 t
6.6lbs
.7086" -.7093"
.7073" -.7077"
.7480" -.7488"
.7464" -.7472"
28 psi
17lbs
2.1 -6.4 psi

Pump gears: 36 bhp (Early)
End play between gears and body
(with gasket) 00000000000000000 00027"
-0007''
Backlash 00o00000000000000000 0000" -0008"
36 bhp (Late)
o0027" -0007''
0000" -0008"
Engine-3
40bhp
00027'' -0007''
0000" -0008"
1500 ENGINES (VARIATIONS TO 1200 ENGINES)
Type 000000000000000000000000
Bore 000000000000000000000000
Stroke 0000ooo0000000000000000
Capacity 0oooo00000000000000000
Bhp (max) 00000000000000000000
Maximum torque 0000000000000000
Compression ratio 0000000000: 0000
Ignition firing point 00000000000000
Valve timing (clearance at 0040"):
Inlet opens o00000000000000000
Inlet closes 000000000000000000
Exhaust opens 0000000000000000
Exhaust closes 0000000000000000
Piston to cylinder clearance 000000000
Upper compression
ring side clearance 000000000000000
51 bhp
3027"
2072"
91.1 cu in
51 at 4000 rpm
74 ft/lb at 2600 rpm
708:1
10° btdc
7°30' btdc ·
37° abdc
44°30'bbdc
4° atdc
00016" -00024"
00027" -00039"
53 bhp 49 bhp (M240)
3027" 3027"
20 72" 2072"
91.1
cu in
91.1 cu in
53 at 4200 rpm 49
at 4200 rpm
78 ft/lb at 2600 rpm
71 ft/lb at 2600 rpm
705:1
606:1
705° btdc 7.5° btdc
7°30' btdc
7°30' btdc
37° abdc 37° abdc
44°30'bbdc
44°30'bbdc
4° atdc
4° atdc
00016" -00024'' 00016" -00024"
00027" -00039" 00027" -00039"
1600 ENGINES (VARIATIONS TO ISOO ENGINES)
Type 000ooo000000000000000000
Bore 00000000000000000000
0. 0
57 bhp (std)
3.36"
9606 cu in
57 at 4400 rpm
57 bhp (M157)
53 bhp (M240)
3.36" 3.36"
9606 cu in
9606 cu in
57 at4400 rpm
53 at 4200 rpm
Capacity 00o0o00000000000000000
Bhp (max) 00000000000000000000
Maximum torque 0000000000000000
Compression ratio 000000000000000
Ignition firing point 00000000000000
82 ft/lb at 3000 rpm 82 ft/lb at 3000 rpm 77 ft/lb at 3000 rpm
707:1 705:1 606:1
oo oo oo
GENERAL ENGINE SPECIFICATIONS FOR ALL
MODELS
Pistons 000000000: 000000000
Type 00000000000000000000
Cylinders 00o00000000000000
Cylinder heads oo000000000000
Valve guides 000000000000000
Valve seats oo00000000000000
Gudgeon pins oo000000000000
Big end bearings 0000000000000
Connecting rods o000000000000
Ohv -horizontally
opposed -air cooled
·Individual -cast iron
with fins
Number
of rings 0000000000o00
Camshaft:
1200 and 1500 (51 bhp)
Cast in pairs -aluminium
alloy with
fins
Replaceable 1500 (53 bhp) and 1600 00o0o
Replaceable
Fully floating -
retained by circlips
3 layer steel backed
H section steel
forgings 9
· Oil pu~p 00000000000000000
Oil cooling 0000000000000000
Engine cooling 00000oo0000o00
Aluminium alloy -
steel reinforcement
2 compression - 1 oil
scraper
Grey cast iron -
three bearing
machined
in block
Grey cast iron -
aluminium alloy
split shell bearings
Gear type -submerged
Cooler
in air stream
Air cooling by fan -
driven by
V-belto

4-Engine
TORQUE WRENCH SETTINGS
Crankcase nuts
................... .
Crankcase bolts and nuts
............ .
Cylinder head nuts
................ .
Rocker shaft nuts
................. .
Flywheel gland
nut ................ .
Connecting rod bolts and nuts
........ .
Generator pulley nut
............... .
Fan
nut ....................... .
Engine carrier nuts
................ .
Clutch to flywheel . . . . . . . . . . . . . . . . .
25 ft/lb
14 ft/lb
23 ft/lb
16 ft/lb
217 ft/lb
24 ft/lb
45 ft/lb
45 ft/lb
18 ft/lb
18 ft/lb
Oil drain plug ................... .
Spark plugs
..................... .
Exceptions to the above:
On 36
bhp engine
Crankcase nuts
................ .
Cylinder head nuts
............... .
Oil drain plug (to August 1959) ·
..... .
Spar.k piug insert
............... .
On 53 and 57 bhp engine
Generator pulley
nut .. : ......... .
Bolt for fan and crank shaft pulley
25 rt/ib
25 ft/lb
22 ft/lb
27 ft/lb
29 ft/lb
52 ft/lb
32 ft/lb
101 ft/lb
I. DESCRIPTION
The air cooled, four cylinder, overhead valve engine is
of the horizontally opposed type·and is basically the same
in
all models.
The crankcase
is two piece and die-cast in light alloy.
As the two crankcase halves are machined to mate together,
replacement can only be made in pairs.
The cylinders attached to the crankcase are
of special
cast iron, incorporating fins on the outside surfaces for
cooling purposes.
As the cylinders are separate, each can be
replaced or interchanged provided the matching piston is
fitted to the appropriate cylinder.
A single removable cylinder head
is fitted to each pair
of cylinders, the head is also cast in light alloy
incorporating fins for cooling purposes. Valve seat inserts
and
valve guides are shrunk into the head.
The crankshaft is mounted in the crankcase and
supported by four main bearings.
In earlier models three of
Engine Assembly.
10
the bearings are of split steel backed lead-bronze type, the
fourth bearing is aluminium alloy
of the bush type;
crankshaft end thrust
is taken by number two main bearing.
Later models have four light alloy lead coated bearings one
of which is the split type; crankshaft end thrust is taken by
number one main bearing. At the. clutch end
of the
crankshaft an oil seal
is fitted, with an oil thrower and oil
return thread incorporated on the pulley end
of the shaft.
The flywheel complete with starter ring gear
is secured to
the crankshaft by a gland nut and located in position by
four dowel pins. Woodruff keys are used
to secure the
timing gear and distributor drive gear to the crankshaft.
The four connecting rods are fitted with detachable
lead-bronze shells in the big end bearing end
of the rod,
with the fully floating gudgeon pin supported in a bronze
bush at the small end
of the rod.
The pistons are fitted with two compression rings and

one oil control ring. The gudgeon pin is retained in the
piston by a circlip located at each end. Pistons are
of light
alloy with steel inserts for reinforcement.
The camshaft
is mounted in the crankcase and
supported by three bearings. A light alloy gear
is riveted to
one end
of the shaft and meshes with the crankshaft gear,
both gears are helically cut.
The cams actuate the valves by transmitting movement
through tappets, push rods and rocker arms.
Oil lubrication to the engine components
is pressure
fed from a gear type pump driven
off the drive end of the
camshaft.
An oil cooler and an oil pressure relief valve are
Engine-5
incorporated in the system; oil drawn from the crankcase is
passed through the oil cooler which is located on the
crankcase
in the air flow. When the oil is cold and thick the
oil pressure relief valve permits oil to partially by-pass the
oil cooler giving direct lubrication to the engine.
Air cooling
of the engine is effected by a fan mounted
on the generator shaft and driven by V-belt from the
crankshaft pulley. Air drawn
in through the fan housing
aperture
is directed by deflector plates around the cylinders
and cylinder heads. Air flow
is controlled by a thermostat
via a throttle ring on the fan housing which enables the
engine
to reach working temperature quickly and maintains
a constant running temperature.
2. ENGINE ASSEMBLY
1200 MODEL$ TO JANUARY, 1963
TO REMOVE
{I) Disconnect the earth cable from the battery
terminal.
(2) Disconnect and remove the oil bath air ·cleaner
assembly and connecting hose to carburettor air intake.
(3) Take
out the securing screws and remove the rear
engine apron.
(
4) Disconnect the leads from the terminals of the
generator, oil pressure switch and ignition coil.
(5) Disconnect the accelerator cable and the choke
cable at the carburettor connections.
(6) Raise the rear
of the vehicle and support on stands.
(7) Loosen
off and remove the exhaust tail pipe
complete with sound neutralising pipe.
(8) Disconnect the two heating control cables at the
control valves, and loosen
off and detach the flexible tubes
at the heat boxes.
(9) Detach the fuel hose at the connection in the cover
plate at the front
of the engine, plug the fuel line to prevent
the loss
of fuel.
(10) Pull
out the accelerator-ca-ble and choke cable (if
fitted) from the fan housing. Take out the securing screws
and remove the front cover plate.
(11) Support the engine from beneath with a trolley
jack.
(12) Loosen and remove the retaining nuts on the
engine support bolts located
top and bottom of the
transmission case and engine flanges.
(13) Ease the engine assembly backward until the
clutch pressure plate assembly
is clear of the gearbox input
shaft.
(14) Lower the assembly and withdraw from the
vehicle.
11
NOTE: It may be necessary to angle the rear of the engine
down to facilitate removal.
TO INSTAL
Installation
is a reversal of the removal proc-edure with
particular attention to the following points:
(I) Ensure that the clutch driven plate hub and the
needle bearing for the gearbox input shaft spigot are
correctly aligned.
Removing or Installing Engine Rear Mounting Bolts.
(Earlier models.)

6-Engine
(2) Check that the transmission case and engine
contact flanges are clean.
(3) Lubricate lightly with high melting point grease the
starter shaft bush located in the transmission housing.
(
4) Clean the gearbox input shaft splines and smear
lightly with high melting point grease.
(5) With the engine supported on a trolley jack move
the assembly into position, raise the engine to align the
gearbox input shaft with the hub of the clutch driven plate.
(6) Engage a gear to hold the gearbox input shaft
stationary.
(7) Move the assembly forward engaging the input
shaft
in the driven plate hub, turn the engine at the V-belt
to engage the splines in the hub.
NOTE: During installation of the engine, the engine weight
must be fully supported by the jack and no stress must
be
placed on the gearbox input shaft or clutch driven plate
hub to avoid the possibility
of damage to the components.
(8) Push the assembly fully home to bring the
transmission case and engine flanges together, enter the two
lower engine support bolts and screw on the nuts but do
not tighten.
(9) Instal the upper engine support bolts and nuts and
tighten them lightly, complete the tightening of the support
bolts and nuts evenly.
(I 0) Connect the accelerator cable and manual choke
cable (if fitted) and adjust.
(11) Check and adjust ignition timing.
TO DISMANTLE AND ASSEMBLE
(I) With the engine removed from the vehicle, drain off
the engine oil into a suitable container.
(2) Take out the securing screws and remove the engine
front cover plate.
(3) Release the securing nut on the generator shaft
pulley and remove the nut, spacers, outer pulley half and
the fan belt.
(4) Disconnect the high tension lead between the
distributor cap and coil, pull free the connectors
at .the
spark plugs and remove the distributor cap.
(5) Take out the securing screws located at each side of
the fan housing, unhook theair controi return spring and
take out the throttle ring securing screws.
(6) Loosen off and remove the strap securing the
· generator to the mounting on the engine, and remove the
fan housing and generator complete from t'he engine.
(7) Loosen ariJ remove the crankshaft pulley securing
bolt, using a suitable puller withdraw the pulley from
the end
of the crankshaft.
(8) Take out the securing screws and remove the cover
plate located below the crankshaft pulley.
12
(9) Remove the fuel lines at the petrol pump and
carburettoi, and loosen off and remove the carburettor
from the inlet manifold.
(10) Loosen off and remove the securing nuts and
screws at the pre-heat pipe and inlet manifold flanges, and
remove the manifold and gaskets.
(11) Loosen
off the clamp bolts at the front exhaust
pipe connections.
(12) Remove the securing nuts at the silencer flanges
and remove the silencer and gaskets.
(13) Loosen off and remove the slotted screw at the
bottom of the heat junction box.
(14) Take out the split pin and detach the connecting
rod from the heat control panel.
(15) Remove the heating junction box and exhaust
pipe.
(16) Detach
h~::ating control cable.
(17) Take
out the threaded ring located in the oil filler
and remove the oil filler and gasket.
(18) Take out the securing screws retaining the heating
channels to the cylinder cover plates, and remove the
heating channels.
(19) Take out the thermostat retaining screw and
unscrew the thermostat from the connecting rod.
(20) Release the connecting rod from the operating
lever located on top of the cylinders.
(21) Loosen and remove the throttle ring shaft nut and
withdraw the shaft.
(22) Remove the thermostat support and securing nut.
(23) Take out the cover plate screws located at each
end of the inlet manifolds and detach both cover plates.
(24) Loosen off the clutch pressure plate assembly
retaining bolts evenly and progressively to avoid stress on
the plate, and remove the clutch assembly.
(25) Ease off the cylinder head cover retaining clip and
remove the cover. ·
(26) Loosen off evenly and alternately the rocker arm
shaft securing nuts and remove the shaft assembly.
NOTE: Later models may be fitted with stud seals which
should be removed.
Unless otherwise stated the dismantling
procedure given for cylinder assemblies
is applicable to
both sides
of the engine.
(27) Loosen off evenly and progressively the cylinder
head securing nuts and withdraw the cylinder head from
the studs.
(28) Remove the push rod tubes andpush rods from
the cylinder block.
(29) Detach the deflector plates positioned below the
cylinders.
(30) Ease the cylinders away from the block and
off
the studs.

NOTE: Mark the piston crowns and cylinders so that they
may be assembled in their original positions.
(31) Using circlip pliers, take out the gudgeon pin
retaining circlips from the pistons.
(32) Heat the piston to approximately 180°F using a
suitable wrap around element or the special tool for this
purpose.
(33) With the piston supported, push out the gudgeon
pin using a drift of the same diameter as the gudgeon pin.
(34} Loosen off and remove the three oil cooler
retaining nuts and remove the cooler and gaskets.
(35) Remove the oil pump cover and gasket after
unscrewing the securing nuts.
(36) Mark the pump gears in relation to the pump
body and remove the gears.
(37) Using the special extractor remove the oil pump
body.
(38) Loosen off and remove the oil filter securing nuts
at the base of the crankcase and remove the cover plate,
gaskets and oil filter.
(39) Remove the fuel pump securing nuts and detach
the pump, remove the flange, gaskets and pump push rod.
(40) Remove the distributor by releasing the retainer
clamping bolt.
(41) Take
out the coil spring from the centre of the
distributor drive pinion.
(42) Turn the crankcase assembly upside down to
allow the drive shaft and washer to fall from the casing.
(43) Using the special wrench and flywheel retainer
tool, remove the
flywhee~ gland nut and detach the
flywheel. Remove the crankshaft oil seal at the flywheel
end
of the crankshaft.
(44) Remove the oil pressure switch from the side
of
the crankcase.
(45) To keep the tappets in position in the right
crankcase half, instal the special retaining springs for this
purpose.
(46) Loosen off and remove the nuts and bolts
retaining the crankcase halves together, using a rubber
mallet gently tap the right half of the crankcase to separate
it from the left half.
NOTE: Do not insert levers or tools between the joint faces
of the casing halves.
(47) Remove the camshaft end plug, camshaft and
tappets from the casing.
(48) Lift out the crankshaft complete with connecting
rods.
(49) Take
out the Woodruff key at the end of the
crankshaft and remove the oil thrower.
(50) Remove No 4 main bearing which is located at the
timing gear
end of the crankshaft.
13
Engine-7
Special Tool used to Retain Cylinders when Removing
Cylinder Head.
(51) Remove the distributor drive gear retaining circlip
from its groove
in the crankshaft.
(52) Immerse
the timing gear end of the shaft in oil
heated to approx. 180°F, using asuitable puller draw the
distributor drive gear, spacer and timing gear from the end
of the shaft.
(53) Loosen off and remove the connecting rods,
marking the rods and bearing caps to ensure assembly in
their original positions.
(54) Remove the bearing shells from the crankcase
halves.
Assembly is a reversal of the dismantling procedure, for
details relating to each sub assembly see under the
appropriate heading.
1200/1500/1600 .YODEIJS FROM JANUARY, '6.1
TO REMOVE
(1) Disconnect the earth cable from the battery
terminal.
(2) Disconnect and remove the oil bath air cleaner
assembly and connection to the carburettor air intake.
(3) Raise the rear
of the vehicle and support on stands.
(4) Take
out the securing bolts and screws and remove
the crossmember at the rear end.
(5) Disconnect the leads from the terminals
of the
generator, ignition coil, oil pressure switch and carburettor
choke unit.

8-Engine
(6) Disconnect the accelerator cable at the carburettor
and remove the spring.
NOTE: On 1600 models it is not necessary to remove the
return spring.
(7) Loosen off and remove the exhaust tail pipes and
damper.
(8) Loosen off and remove the. two upper engine
mounting bolts and nuts.
(9) Withdraw the accelerator cable and detach the fuel
hose at the connection in the front engine cover plate. Plug
the fuel line to prevent the loss
of fuel.
(10) Disconnect both heating control cables and the
flexible pipes from the heat exchangers.
(11) Support the engine from beneath with a trolley
jack, and loosen off and remove the two lower engine
mounting bolts and nuts.
NOTE: On 1600 models, the engine is supported by a
crossmember and rubber mountings at the crankshaft
pulley end of the engine. Take out the securing bolts
attaching the crossmember to the engine, remove the
securing bolt and nut from each rubber mounting and
detach the crossmember.
(12) Ease the engine assembly backward until the
clutch pressure plate assembly
is clear of the gearbox input
shaft.
(13) Lower the assembly and withdraw from the
vehicle.
RUBBER MOUNTING
FRAME MEMBER
Rear Engine Mounting Location and attaChment. (Except
1600 models.)
14
TO INSTAL
· Installation is a reversal of the removal procedure with
particular attention to the following points:
(1) Ensure that the clutch driven plate hub and the
needle bearing for the gearbox input shaft spigot are
correctly aligned.
(2) Check that the transmission .case and engine
contact flanges are clean.
(3) Examine the clutch release bearing and release ring
for cracks or wear.
If the release bearing is fitted with a
plastic ring, roughen the ring with emery cloth and smear
with a molybdenum-disulfide based lubricant.
(4) Lubricate lightly with high melting point grease the
starter shaft bush.
, (5) Clean the gearbox input shaft splines and lightly
apply a molybdenum-disulfide powder.
(6) With the engine supported on a trolley jack move
the assembly into position, raise the engine to align the
gearbox input shaft with the hub
of the clutch driven plate.
(7) Engage a gear to hold· the gearbox input shaft
stationary.
(8)
Move the assembly forward engaging the input
shaft in the driven plate hub, turn the engine at the V-belt
to engage the splines in the hub.
NOTE: During installation of the engine, the engine weight
must be fully supported by the jack, and no stress. mustbe
placed on the gearbox input shaft or clutch driven plate
hub, to avoid the possibility of damage to the components.
(9) Push the assembly fully home to bring the
transmission
case and engine flanges together. Enter the
two lower engine mounting bolts and nuts but do
not
tighten.
(10) Instal the upper engine mounting bolts and nuts
and tighten them lightly, complete the tightening
of all the
mounting bolts and nuts evenly.
NOTE: On 1600 models, instal the engine support
crossmember and rubber mountings.
(11) Connect and adjust the accelerator cable at full
throttle.
(12) Check and adjust ignition timing
as described
under the appropriate heading.
TO DISMANTLE AND ASSEMBLE
(1) With the engine removed from the vehicle, drain off
the engine oil into a suitable container.
(2) Disconnect and remove the connecting hoses
between the fan housing and heat exchangers.
(3) Loosen
off and detach the front engine cover plate.

(4) Loosen off and detach the cover plate above the
crankshaft pulley.
(5) Take out the securing screws and remove the
manifold preheater pipe sealing plate.
{6) Loosen
off and detach the rear engine cover plate.
(7) Loosen off heat exchanger clamps and the clips
connecting the warm air channels.
(8) Unscrew and remove the securing nuts attaching
the silencer flanges to the cylinder heads, and take off the
pre-heater adaptor pipe.
(9) Take out the four screws in the manifold pre-heater
pipe.
{10) Remove the silencer and gaskets.
{II) Release the securing nut on the generator shaft
pulley and remove the nut, spacers, outer pulley half and
the fan belt.
{12) Disconnect the cables connecting the ignition coil
to the distributor' pull free the connectors at the spark
plugs and remove the distributor cap.
{13) Take
out the securing screws located at each side
of the fan housing, unhook the air control return spring and
take
out the throttle ring securing screws.
NOTE: On later models fitted with modified air control
system, remove the right
rear lower warm air duct and
remove the thermostat securing
screw. Unscrew and detach
the thermostat from the
end of the connecting link and lift
thefan housingand generator from the engine.
{14) Loosen off and remove the strap securing the
generator
to the mounting on the engine and remove the
fan housing and generator complete from the engine.
{I 5) Remove the intake manifold and intermediate
exhaust flange securing nuts, detach the manifold and
remove the cylinder head sealing rings.
{16) Take out the screws in lower part of warm air
channel and remove the exhaust pipe clamps. Remove the
heat exchangers by easing forward.
(I 7) Remove both air guide plates and take off the
cylinder cover plates.
{18) Loosen and remove the crankshaft pulley securing
bolt, using a suitable puller withdraw the pulley frorri the
end of the crankshaft.
{19) Take out the securing screws and' remove the
lower crankshaft pulley cover plate.
{20) Ease off the cylinder head cover n:itairiing clips
and remove the covers.
{21) Loosen off evenly the rocker arm shaft securing
nuts and remove the rocker shaft assembly. Take out the
stud seals.
·{22) Withdraw the push rods from the cylinder heads.
{23) Loosen
off and remove the cylinder heads
retaining nuts and washers and withdraw the cylinder heads
from the studs. ·
15
Engine-9
{24) Detach the push rod tubes and the deflector plates
from below the cylinders.
(25) Ease the cylinders away from the block and
off
the studs.
NOTE: Mark piston crowns and cylinders to ensure
installation in the original positions.
{26) Using circlip· pliers, take out tpe gudgeon pin
retaining circlips from the pistons.
{27) If the gudgeon pins cannot be finger pushed from
the pistons, heat the piston using a wrap around element or
the special tool for this purpose.
(28) With the piston fully supported, push but the
gudgeon pin using a drift
of the same diameter.
{29) Loosen off and remove the three oil cooler
retaining nuts and remove the cooler and gaskets.
{30) Remove the oil pump cover and ·gasket after
unscrewing the securing nuts.
{31) Take out the pump gears and withdraw the pump
body using the special extractor for this purpose.
{32) Loosen
off and remove the oil filter securing nuts
at the base of the crankcase and remove the cover plate,
gaskets and oil filter.
{33) Remove the fuel pump securing nuts and. detach
the pump, remove the flange, gaskets and pump push rod.
{34) Remove the distributor by releasing the retainer
nut.
·{35) Take out the coil spring from the centre of the
distributor drive pinion.
{36) Turn the crankcase assembly upside down to
allow the drive shaft and washer to fall from the casmg.
{37) Loosen
off and remove the clutch assembly and
retaining bolts from the flywheel.
{38) Using the special wrench and flywheel retainer
tool, remove the flywheel gland nut and detach the
flywheel. Remove the crankshaft. oil seal at the flywheel
end of the crankshaft.
{39) Remove the oil pressure switch from the
crankcase. 1
(40) Pull off the oil filler connecting hose and take out
the threaded ring to detach the oil filler.
{41) To keep the tappets in position
in the right
crankcase half, instal the special retaining springs for this
purpose.
{42) Loosen off and remove the nuts retaining together
the two crankcase halves and using a rubber mallet gently
.tap the right half of the crankcase to separate it from the
left. ·
NOTE: Do not insert levers or tools between the joint faces
of the casing halves.
(43) Remove the camshaft end plug, camshaft and
tappets from the casing.

10-Engine
(44) Lift out the crankshaft complete with connecting
rods.
(45) Take
out the Woodruff key at the end of the
crankshaft and remove the
oil thrower.
(46) Remove No 4 main bearing and the distributor
drive gear retaining circlip.
(47) Immerse the timing gear end
of the crankshaft in
oil heated to approximately
180°F, using a suitable puller
draw the distributor drive gear, spacer and timing gear from
the end
of the shaft.
(48). Remove No 3 main bearing from the crankshaft
journal.
(49) Loosen
off and remove the connecting rods,
marking the rods and bearing caps to ensure assembly in
their original positions.
(50) Remove No 1 main bearing and the shells
of No 2
main bearing.
Assembly
is a reyersal of the dismantling procedure.
For details relating
to each sub assembly, see under the
appropriate heading.
3. ROCKER ARMS AND SHAFTS
1200 MODELS TO }A!\'VARY, .l963
TO DISMANTLE AND ASSEMBLE
(1) With the rocker arm shaft assemblies removed from
the engine
as described earlier, remove the circlips at each
end
of the shaft.
(2) Slide
off the shaft, the washers, rocker arms and
support brackets.
NOTE: Before reassembling check the shaft, adjusting
screws and arm ball sockets for wear. Renew worn
components
as necessary.
(3) Instal the rocker arms and support brackets on the
shaft, with the washers located at the sides
of the rocker
arms which bear against the four circlips.
NOTE: The washers are fitted in a set of three in each
position with the waved-washer inserted between two flat
washers.
(4) With the washers in position instal the circlips at
each end
of the shaft.
1200jl500jl600 MODELS FROM JANUARY, '63
Modification to the rocker arm assembly at:
1200cc- December 1963, Chassis No 1219722
(Erigine No 8247714)
1 SOOcc -June 1963, Chassis 1139422 (Engine No
0243326)
Valve angle has now been increased to
9°30' from 9°,
and parts of the valve gear changed. Modified cylinder
heads can
be identified at the embossed casting number,
located on the head between the rocker shaft studs.
In the
case
of 1200cc cylinder heads the number will be suffixed
by the letter
C, and with 1 SOOcc cylinder heads the letter
A.
Note that the rocker arm assembly securing nuts which
must be
of the correct grade are copper in colour. Also that
rocker arms differ in dimension and are therefore not
interchangeable between engines
of different capacity.
Rocker shaft position has been aitered slightly with the
16
bores in the supports for the rocker shaft now off centre.
The supportsare marked with the word TOP which must be
positioned to the outside on installation. The rocker arms
are modified on the 1
SOOcc and can be identified by two
forged lines on·the rib
of the arm. Push rod length has been
increased and the new rods can be identified by knurling on
tht. :
od shaft.
From January 1964, rocker arms have been provided
with a drilling
to allow oil flow to the contact area of the
adjusting screw and valve stem. This modification reduces
valve gear noise and wear on the valve stem ends. An oil
deflector ring
is fitted to the valve stems to minimise the
passing
of oil through the valve guides. This modification
has brought about the shortening
of the valve guides by
.040". The oil deflector ring and modified rocker arms can
only be installed on engines having cylinder heads with the
9°30' valve angle, shortening of the valve guides will be
necessary and can be accomplished by using a suitable
milled cutter.
It is important that in the case of engines fitted with
slotted rocker shaft supports, that the supports are installed
with the chamfered edges outwards and the slot upward.
Two supports
of the same type only must be installed to
the rocker shaft.
From June 1966, Chassis No 216173747 (Engine No
HOI76639), the push rods
of the 1500cc engine have been
increased in length
and diameter. New and old type push
rods can be installed
if necessary in one engine.
TO DISMANTLE AND ASSEMBLE
(1) With the rocker arm shaft assemblies removed from
the engine
as described earlier, remove the circlips at each
end
of the shaft.
(2) Slide
off the shaft the washers, rocker arms and
support brackets. Note the order in· which the rocker aril1s
are removed.
NOTE: Before reassembling, check the shaft, adjusting

screws and arm ball sockets for wear. Renew worn
components
as necessary.
(3) Instal the rocker arms and support brackets on the
shaft in their original positions, and with the word TOP on
the support brackets outwards.
(4) The washers should be fitted
in sets of three with
the waved washers inserted between the flat washers. Each
set of three washers should be positioned at the sides of the
rocker arms adjacent to the circlips.
(5) With the washers in position instal the circlips at
each end
of the shafts.
4. t::VLINDER HEADS AND VALVES
1200 ~lODELS TO ].4Nl!ARY, 1963
"fO 'DISMANTLE
(1) Remove the cylinder head assemblies from the
engine
as described earlier and place them on a clean bench.
NOTE: The following procedure is applicable to both
cylinqer heads.
(2) Using a suitable valve spring compressor, compress
each
valve spring in turn to remove the valve retaining
collets, remove the compressor.
(3) Lift
off the valve spring retainer and spring.
(4) Remove any burrs on the valve stem collet grooves
to prevent damage to the valve guides when the valves are
removed.
(5) Remove the valves from the cylinder heads and
place them in arack
so that they can be installed in their
original positions when reassembling the cylinder head.
TO CLEAN AND INSPECT
(1) Clean each valve thoroughly and renew any that are
burned or cracked across the face, or that have berit or
warped stems.
NOTE: Maximum permitted valve stem rnn-out is .0004".
(2) Remove the carbon deposits from the combustion
chambers and ports and check the condition
of the valve
seats in the head.
If the seat inserts are cracked, badly
burnt, or the outer edge
of the top chamfer exceeds the
outer diameter
of the valve seat insert, a reconditioned or
new cylinder head should be fitted.
NOTE: The fitting of valve seat inserts is a specialist job
requzrzng special equipment and therefore is not
recommended.
(3) Check the cylinder heads for cracks in the
combustion chambers and ports, cracked cylinder heads
should be replaced.
(
4) Check that the valve guides are not excessively
17
~HAIRPIN
-CLIP
Engine-11
. (.')
SPACER WASHERS< c _WAVED WASHER
~ . .
~-ROCKER ARM
SUPPORT -1-.'.lli-
~~~~~, I
SPACER WASHERS
ROCKER ARM
---WAVED WASHER
c:;:::::::..___ HAIRPIN CLIPS
c:c:-~
0
o-· WAVED WASHER
ROCKER SHAFT
~- ROC~ER ARM
SPACER WASHERS
SUPPORT
~- ROCKER ARM
SPACER <~0-·
WASHERS ""0. WAVED WASHER
~'-- HAIRPIN CLIP
Exploded Rocker Shaft Components. (Note the word TOP
on rocker supports.)
worn, the maximum permitted clearance between the valve
stem and guide should not exceed .0063 ".
NOTE: The fitting of valve guides is a specialist job ·
requiring · special equipment and therefore
is not
recommended.
(5) Check the valve spring against the specifications. If
a spring tester is not available, test by comparison with a
new spring.

12-Engine
TO REF ACE VALVES AND VALVE SEATS
(1) The valve seats in the cylinder head should be
refaced with a 45° seat cutter when badly pitted or burnt.
NOTE: Only sufficient metal should be removed with the
seat cutter to obtain a concentric seating surface clear
of
pits or other damage.
(2) Using a 75° cutter chamfer the lower edge of the
valve seat face.
(3) Using a 15° cutter chamfer the upper edge of the
valve seat face.
NOTE: It is essential that the correct seat width is obtained
fl- COTTERS -~~
RETAINER
~
SEAL
~
"SPRING
~
VALVE
~
Valve and Spring Components.
18
during the refacing procedure. The inlet seat width should
be . 051" -. 063" and the exhaust seat width should be
.067" -.079". The seat widths can be na"owed by
operations (2) and (3) and increased
by operation (1 ). The
outer edge of the upper 15° chamfer should not exceed the
outerdiameter
of the seat insert.
(4) Pitted or burnt valves should be. refaced with a
valve refacing machine provided the pitting or burning of
the seat face is not extensive when the valve should be
replaced.
NOTE: Valve seat widths for both inlet and exhaust valves
should be the same as specified earlier for the cylinder head
valve seat inserts.
(5) Correctly refaced valves and valve seats should
require very little lapping to obtain accurate seating. Ensure
that the valve is frequently lifted clear of the seat and
rotated during the lapping operation to avoid grooving the
seat faces.
(6) With the grinding compound thoroughly cleaned
from the valves and seats, check the fit
of the valves to the
valve seats.
(7) Smear the
valve face with be.aring blue and insert
the valve into position, using light hand pressure rotate the
valve a quarter turn only.
(8) Remove the
vaive and inspect the faces. A correctly
seated valve should have evenly transferred the blue to the
valve seat.
TO ASSEMBLE AND INSTAL
Assembly and installation is a reversal of the
dismantling and removal procedures with attention to the
following points:
(1) Ensure that all grinding compound has been
cleaned from the components.
(2) Check that the valve retaining collets are correctly
seated
in the spring seat and valve grooves.
(3) Check that the cylinder head holding studs are tight
in the block.
(4) Instal a new gasket between the cylinder head and
the cylinder shoulder.
NOTE: Gaskets are not fitted between the cylinder head
andthe top edge of the cylinder.
(5) Fit new seals to the push rod tubes and instal them
with the tube seam facing upwards. If necessary stretchthe
tubes to 7.11" -7.16" to ensure positive sealing, but use
care to avoid cracking the tubes.
(6) Place the cylinder head in position over the studs,
smear the cylinder head securing nuts with graphite paste
and instal them on the studs after first fitting the
nut
washers.

Engine--13
I
I
Underside of Cylinder Head Showing Valve Arrangement.
4 2 3
Method and Sequence for Tightening Cylinder Head Nuts .. First Tightening 7ft/lb.
19

14.-Engine
(7) Tighten the cylinder head nuts evenly and
progressively to a torque
of 7 ft/lb working from the centre
outwards on the securing nuts located
in the rocker shaft
and
valve spring chamber. Carry out the same procedure
with the securing nuts located
in line with the sparking plug
apertures.
(8) Fully tighten the securing nuts to a torque
of 23
ft/lb working from the centre outwards but taking alternate
nuts
in each row to ensure that the pressure is evenly
exerted over the whole
of the head.
(9) Instal the rocker arm shaft assembly and ensure
that the ball ends
of the push rods are located centrally in
the rocker arm sockets.
NOTE: Prior to fitting the rocker arm assembly instal the
stud
seals to those models to which it is applicable.
(1 0) Check that the rocker arm adjusting screws are
contacting the
valve stems just right of the stem centre, this
is to assist valve rotation during operation.
If necessary move the rocker arm shaft
in the support
bracket holes
to obtain the correct position prior to
tightening the securing nuts.
(11) Carry out the procedure for adjusting the
valve
clearances as described under the section VALVE TIMING
AND TAPPETADJUSTMENT.
(12) Immerse new cylinder head cover gaskets in
slightly warmed water before cementing the gaskets to the
covers. Ensure that the cement fully covers one face
of the
gasket before attaching it to the cover.
1200/1500/1600 M.ODEI.S FROilt JANUARY, '63
Engines fitted with the older type of cylinder head can
be identified by the shape of the rocker shaft stud bosses,
the old type head has round bosses whereas the new type
head has square bosses.
On the old type of cylinder heads
cooling efficiency can
be increased where the vehicle is
driven under abnormal conditions, eg hard driving over long
periods
in a strong head wing and high air temperature.
Drill three .40" diameter holes through the two ribs located
near the inlet port, this will reduce the cylinder head
temperature at full load.
On all engines fitted with the new type of cylinder
head (square rocker shaft stud bosses) the
valve clearance
should
be set at .004" for both inlet and exhaust valves,
with the engine in a cold state or the oil temperature not
exceeding 50°C.
Valve clearances for all other engines remain as
specified. In the case of engines fitted with a sticker on the
fan h()using and/or a clip on the rocker shaft
valve
clearances must be adjusted accordingly.
On 1500cc engines from August 1964, Chassis No
265000335 (Engine No 627579) modified valve caps and
20
springs are fitted and can be identified by colour marking
of either· silver-gray or violet paint. The new type springs
and caps can
be fitted in place of the old units provided
they are installed in complete sets.
On 1200cc engines where the.valves have worn stem
ends, a detachable
valve cap can be installed on the stem to
make the valves
se~iceable.
In August 1965, from Chassis No 216000001 (Engine
No H0000001) inlet valve diameter was increased to 1.40"
and the exhaust
valve diameter to 1.26".
TO DISMANTLE
(1) Remove the cylinder head assemblies from the
engine
as described earlier and place them on a clean bench.
NOTE: The following procedure is applicable to both
cylinder
heads.
(2) Using a suitable valve spring compressor, compress
each
valve spring in turn to remove the valve retaining
collets.
(3) Remove the compressor and lift
off the spring cap
and spring.
(4) Remove any burrs on the
valve stem collet grooves
·to prevent damage to the
valve guides when the valves are
removed.
(5) Remove the
valves from the cylinder heads and
place them in a rack
so that they can be installed in their
original positions.
TO CLEAN AND INSPECT
(1) Clean each valve thoroughly and renew any that are
burned or cracked across the seat face, or that have bent or
warped sterns.
NOTE: Maximum permitted valve stem run-out is .0004·:
(2) Remove the carbon deposits from the combustion
chambers and ports, check the condition
of the valve seats
in the head.
If the seat inserts are cracked, badly burnt or
the outer edge
of the top chamfer exceeds the outer
diameter
of the valve seat insert a reconditioned or new
cylinder head should be fitted.
NOTE: The fitting of valve seat inserts is a specialist job
requiring special equipment and therefore
is not
recommended.
(3) Check the cylinder heads for cracks, also in the
combustion chambers and ports. Cracked cylinder heads
must be replaced.
(4) Check that the
valve guides are not excessively
worn, the maximum permitted rock between the
valve stem
and guide
is .0063 ". .