Aircooled VW South Africa

Hi All,
Well I finally refitted the motor in my bus this morning. Went in surprisingly easily but when I bolted everything up tight I couldn't turn the engine over (by hand). Loosened off again, have it a wiggle and tried again. I managed a bit of movement but could feel it binding on something. Long story short I pulled the engine out again and found score marks inside the bell housing where the edge of the flywheel had made contact.

Ive just had the flywheel off to renew the crankshaft seal and adjust end float but it went back on with no problem. Is it possible that it hasn't seated home all the way? Even with all that torque on the flywheel nut? I can't see what would stop it from going all the way back on. Does anyone have a measurement for how proud the flywheel should be of the face of the engine case?

Thanks all,

Mike

It sounds like you are reinstalling the same engine that was in the bus before? Is that correct?

In that case, I have no ideas for you. However, the usual cause of this is trying to fit a 1300/1500/1600 engine on a 1200 gearbox. In that case the bellhousing needs to be flycut slightly to allow the bigger flywheel in, or you need to fit a 1200 flywheel to the engine. This issue can also arise with 6V vs 12V flywheels.

If I'm off track here, maybe give us more info about the bus: year, transmission, engine, etc.

Hi Fig,

The bus is a '62, but it has a 1600 engine in it, and yes, I'm fitting the same engine and flywheel that I removed a coupla months ago. I'm not sure what the gearbox is, but it all fitted before. A while back it did have a 6v flywheel running on a 12v starter. The PO had upgraded the starter but not the flywheel. But that's all academic: the setup I'm putting in now is exactly what I pulled out, bar a new clutch and a few flywheel shims.

Wrong clutch/pressure plate combo for your gearbox ??

Can't see how that would cause the flywheel to sit further out???

doesnt make sense...

The only thing I can think is that it hasnt seated against the bellhousing properly and is thus a little at an angle, forcing the flywheel onto the gearbox.
Climb under the bus again and check that the case fits neatly onto the box

Further than that, I am out of ideas... as you said, it worked before

I for one am verry keen to find out why this is happening Also make sure you are using the correct size bolts to bolt up ,to thin or wrong bolt might be the issue.

Its very easy...

The PO has fitted an 2lt clutch and fly wheel.

Instead of clearing the bell housing with a angle grinder, like most of us do,

He probably turned the crank and cut the bell housing with the flywheel.

now you have fitted spacers to repair end play, and the fly wheel is protruding a mill or two more into the bell housing, where the clearance has not yet been done.

Take it out and clear the bell housing a bit more, you do this by spraying the inside with Matt black can spray, fit the motor, remove the motor, and grind the silver marks.

OR....

Do what the PO did, crank the engine when you systematically tighten the 4 bolts,this will clear it too.

Herman

Thanks Herman, you were spot on. I clearanced it using the flywheel itself, systematically tightening the bolts. It didn't need much. Thanks again, so glad I didn't have to remove the flywheel again!

You more then welcome.

Glad I could save you the effort......



Herman

Herman have you any idea on Saturdays lotto numbers ? You better pm em to me.....

splitfan wrote:Herman have you any idea on Saturdays lotto numbers ? You better pm em to me.....

Nevermind lotto numbers,@retrovan can you organize us a Government tender or 2????????

Donner,
Herman, you're a sharp pencil boet..