Engine endfloat HELP PLEASE!!!!

psimitar · 2012-04-23T14:54:13+00:00

Hiya, So I have a very interesting endfloat problem. I rebuilt the 1200 engine that came with my Beetle last year and as I was in a bit of a rush didn't notice the endfloat problem that will follow. Fortunately the engine never started 😉 So take a look at the below picture of the crank installed in the case. So hopefully the numbers are visable but as you can see the no1 crank journal extends 3.7mm from the thrust bearing face and the journal is approximately 54.4mm in diameter. Then the smaller diameter nose of the crank is 53.4mm and is 5.5mm long from the step down from the journal diameter. The flywheel boss is 8mm deep and has a small change is diameter 4mm into the 8mm crank nose hole. Right. So can anyone explain to me why my crank is like this because the currently available shims only have an ID of 53.75mm or maybe close to 54mm but obviously not enough to fit over the crank journal that extends for the thrust bearing and be able to sit flush against the thrust bearing face. I'm wondering if there was some kind of intermediate engine changes from the early 1100 and 1200 cranks with 48mm endfloat shims to the later 53.75mm shims of all other T1 engines? What with the step in the flywheel and the crank nose lining up it's almost like an 'O' ring used to squish up in here and that journal sized ID shims where used. Please, please, please can anyone help me in figuring this out cos at the moment the only option I can think of is having the crank nose ground so that the 53.4mm nose extends back to just inside the thrust bearing and therefore allowing the later shims to fit correctly. If you're wondering with the flywheel fitted up I have roughly 1mm of endfloat but this is without the metal or paper gasket fitted to the end of the crank nose. HELP!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

psimitar Son of Jim - Creator of Good

2,506 posts · joined Jan 2009 · 11 Jun 2012, 10:23 pm

#907464

Just in case anyone was wondering the machined groove in the 6v flywheel seems to be working. time will tell if the O ring has enough purchase to stop the oil leaking.

Cheers for all the help 🙂

madness is in the eye of the beholder 👍

Lucky Phil Wolfsburg Wizard

480 posts · joined Aug 2010 · 11 Jun 2012, 10:49 pm

#907471

Crikey, what an evolution!
Hope it works.

psimitar Son of Jim - Creator of Good

2,506 posts · joined Jan 2009 · 12 Jun 2012, 1:30 am

#907482

Lucky Phil wrote:Crikey, what an evolution!
Hope it works.

Yea, what's even funnier tho is that the machinist took a bit off the inside face of the flywheel so the new shims I bought were too much and I ended up using the old shims. I may have been able to use the metal gasket with the new shims but the old ones came up at 0.1mm so spot on 🙂

madness is in the eye of the beholder 👍