I'm assembling a new engine (1600 type 1) and about to fit the flywheel. I have measured the endfloat to be 0.65mm. I understand three shims must be used and they come in a number of sizes from 0.24mm - 0.36mm. The assembled end float should be 0.07 - 0.13mm. So for minimum end float I need 0.65 - 0.07 = 0.58mm worth of (3) shims.

Well this aint possible with three shims.....

Any clues or ideas of what is up????? Can I use two shims???

did you get a new thrust bearing cut in???

Sounds like you need to get the case machined and a new thrust bearing put on??


But..... have you fitted the fly wheel???

Aint you suppose to measure end play with the fly wheel on???

the flywheel has to be fitted and the gland nut torqued to 300ft/lbs, then you can start measuring the end play, which you either use a dial gauge or a special tool which lets you use feeler gauges.

You should be using 3 shims, it acts as a sort of buffer between the rotation of the flywheel and the thrust surface on the #1 bearing.

did u fit new main bearings as Barry said....

fit the flywheel to the crank without seal or shims then check the total end float...

Thanks for the replies.

A bit more info. I have used a new empi aluminium case and a 74mm stroke crank. New std bearings - which fitted well.
I did fit the flywheel, although I didn't fully tourque it up - just a firm nip-up. (if it was not tight enough I guess the end float would be increased)

I measured the end float with a dial indicator clamped to the flywhel and measured it on the case/gearbox flange. No seal fitted.

I suggest you go along to a VW shop and have it checked out