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Page 4
VW Type 4 Engine:    Previous...   1 | 2 | 3 | 4 | 5 |   Next...
 

Modify VW Type 1 Oil Pump For Use In VW Type 4 Engine
 
This is to show how a VW Type 1 Flat Cam Oil Pump(#111 115 107 AHD) can be modified for use with a VW Type 4 engine. The VW Type 4 oil pumps have been out of production for quite some time! The Type 1 Pump used must be for a late 1970-71 engine with a Flat Cam Gear! It can be a 26mm(#111-115-107-AKHD) or a 30mm(#111 115 107 AHD) pump for a Flat Cam Gear. For this engine a Schadek 30mm pump has been selected due to the large remote Mesa Oil Cooler used... also the 4 case studs must be replaced with longer ones(35mm to 40mm)! The Type 4 Cam Gear must also have its bolt holes recessed so that there is no interference with the bolt heads and pump body>

To modify the 30mm Type 1 pump is quite simple... the upper pump body drive gear housing must be shaved about 0.030" to clear the Cam Gear face. The drive gear must have its shaft pressed in so that the shaft is flush with the face of the drive gear and the drive tang shaved about 0.020" so that there is no interference fit with the drive tang and Cam Gear slot. The lower pump body fixed gear must be shaved about 0.010" so that bolt heads of the Cam Gear do not interfere with the fixed gear body housing.

It should be noted that this pump can be purchased already modified... but it is very expensive!
 
Click for larger view...

October 21, 2012
VW Type 4 - Cam Gear must be modified by recessing bolt holes about a 1/16" so the they clear the lower pump body.

Click for larger view...

October 21, 2012
VW Type 4 - Cam Gear front view. oil holes!

Click for larger view...

October 21, 2012
VW Type 4 - Cam Gear rear view.

 
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October 21, 2012
VW Type 1 - 30mm Flat Cam Oil pump... #111 115 107 AHD30. Rear view. The upper pump body that supports the drive gear must be shaved about 0.030". The drive gear must have the shaft pressed in to where its flush with the face of the drive gear!

Click for larger view...

October 21, 2012
VW Type 1 - 30mm Flat Cam Oil pump... #111 115 107 AHD30. Rear view showing the pump, upper and lower drive gear and fixed gear body after shaving. Also the drive gear has the shaft now flush with the face of the gear. This can be done with a basic vice. The tang on the shaft must be shaved a bit to ensure that it does not interfere with the Type 4 Cam Gear slot.

Click for larger view...

October 21, 2012
VW Type 1 - 30mm Flat Cam pump body showing side view after shaving. The lower body fixed gear must be shaved so the the Type 4 Cam Gear Bolt heads do not interfere with the pump body!

 
Click for larger view...

October 21, 2012
VW Type 1 - 30mm Flat Cam pump body showing installation in Type 4 case. Note a check must be made to ensure that the inlet and outlet oil holes in the pump body line up with the inlet and outlet oil holes in both sides of the Type 4 engine case...

Click for larger view...

October 21, 2012
VW Type 1 - 30mm Flat Cam pump body showing installation with the Type 4 Cam Gear. Note that the drive gear should have about 0.25" protruding out of the pump body, with the drive tang not in the Type 4 Cam Gear slot(Cam Gear face).

Click for larger view...

October 21, 2012
VW Type 1 - 30mm Flat Cam pump drive gear protrusion measurement is 0.0248"... just right

 
Click for larger view...

October 21, 2012
VW Type 1 - Oil Pump Cover, must be modified for use with the Type 4 engine. The top right hand corner will be shaved a bit to fit the Type 4 case bolt boss... very simple!

 

 
Modify VW Type 4 Engine - 8mm Rockers for Swivel Foot Adjusters and Valve Train Geometry
 
VW Type 4 Engine Valve Train Geometry Explained
Primary objective is for the builder to attain the ability to properly set up the valve train of a Type 4 engine equipped with a performance camshaft and upgraded valve train components. Secondary objective: To obtain understanding of the positive and negative effects of valve train geometry on engine longevity, reliability and overall performance.

Basic Tools Required:
Adjustable pushrod tool with span from 260mm - 278 mm
Dial indicator with at least 1 of measuring travel
Cutting tool adequate for cutting of the pushrods(steel fuel lines)
Vernier caliper with 11 of travel
Various hand tools for installation of measurement devices and checking components

Components needed:
Type 4 engine completed to Longblock - equipped for SOLID LIFTERS...(without pushrod tubes installed)
Rocker shafts complete with modified 1.7L 8mm rocker arms and solid spacers
Swivel Foot valve adjusters with nuts (Ford-Soobie Type used)
Set of 8 cut to length pushrods with one set of tips installed
Heavy duty 8mm rocker studs, installed

Why valve train geometry is so important and why it MUST be checked when any of the following characteristics of your engine have been changed.
- Performance camshaft installed and matching aftermarket lifters(no matter how mild!)
- Cylinder length altered(new)
- Cylinder shims added(adjust for C.R.)
- Cylinder head gaskets removed (per the VW bulletin)
- Cylinder heads resurfaced
- Valve seats cut (dropping the installed heights of the valves)
 
Modify VW Type 4 Engine - 8mm Rockers for Swivel Foot Adjusters
 
Click for larger view...

November 24, 2012
Ford-Soobie Type swivel foot adjuster on the left! Elephant Foot Type on the right... this adjuster has a tendency to break. A more expensive solution is to use a Porsche 911 swivel foot adjuster. The nice thing about the Ford-Soobie Type adjuster is the oil hole and when the sphere is not loaded, oil can reach the ball thanks to the oil channels in the rocker arm and ESCAPE AROUND IT.

Click for larger view...

November 24, 2012
Ford-Soobie Type swivel foot 8mm adjuster... acquired from CIP.com under the EMPI brand name. EMW also sells them along with Great Plains. To use any type of swivel foot adjuster a mod must be done to the Rocker arms. The adjuster boss is to thick and about a 1/16" must be shaved off of the bottom. The thickness of the captive collar on the Ford-Soobie type adjuster dictates the need to reduce the thickness of the threaded bore of the rocker that accepts the adjuster

Click for larger view...

November 24, 2012
VW Type 4 1.7L 8mm rocker arm needs to have 1/16" shaved from the adjuster boss! Shims could be added but they can cause problems getting the valve train geometry right... so its best to remove the bottom part of the rocker! All of the rocker arms were checked and found to have a thickness that was not consistent. So a decision was made to make them all a consistent thickness of 0.445".

 
Click for larger view...

November 24, 2012
VW Type 4 1.7L 8mm rocker arm has 1/16" shaved from the adjuster boss! This view shows the bottom of the boss after it had the thickness reduced to 0.445"!

Click for larger view...

November 24, 2012
VW Type 4 1.7L 8mm rocker arm has 1/16" shaved from the adjuster boss! This view shows the bottom of the boss after it had the thickness reduced to 0.445" and the Ford-Soobie adjuster added!

Click for larger view...

November 24, 2012
VW Type 4 8mm rocker arm assembly with the Ford-Soobie adjusters added! The rocker arm shafts have been polished with 320 emery cloth!

 
Click for larger view...

November 24, 2012
VW Type 4 8mm rocker arm assembly with the Ford-Soobie adjusters added! The rocker arm shafts have been polished with 320 emery cloth! Also note the solid spacer that is used instead... of the stock VW spring and washers that were used in the engine with solid lifters and aluminum pushrods. The engine with hydraulic lifters had the spacers along with steel pushrods!

Click for larger view...

November 24, 2012
VW Type 4 8mm rocker arm assembly with the Ford-Soobie adjusters added! The rocker arm shafts have been polished with 320 emery cloth! Also note the solid spacer that is used instead... of the stock VW spring and washers that were used in the engine with solid lifters and aluminum pushrods. The engine with hydraulic lifters had the spacers along with steel pushrods!

Click for larger view...

November 24, 2012
VW Type 4 - solid spacers that is used instead... of the stock VW spring and washers that were used in the engine with solid lifters and aluminum pushrods.

 
Click for larger view...

November 26, 2012
VW Type 4 - head with modified swivel foot adjusters added. Also note the solid spacer that is used instead... of the stock VW spring and washers that were used in the engine with solid lifters and aluminum pushrods. The engine with hydraulic lifters had the spacers along with steel pushrods!

Click for larger view...

November 26, 2012
VW Type 4 - head with modified swivel foot adjusters added. Also note the solid spacer that is used instead... of the stock VW spring and washers that were used in the engine with solid lifters and aluminum pushrods. The engine with hydraulic lifters had the spacers along with steel pushrods!

Click for larger view...

November 26, 2012
Adjusteble pushrod tool made used to measure the new chromoly pushrods. Took a stock aluminum used pushrod(270mm)... cut 3/4" out and then tapped each end for a 1/4" bolt, added 2 jam nuts.

 
Click for larger view...

November 26, 2012
Adjusteble pushrod tool made used to measure the new chromoly pushrods. Took a stock aluminum used pushrod... cut 3/4" out and then tapped each end for a 1/4" bolt, added 2 jam nuts. Note the new chromoly pushrods... along with the uninstalled tip ends.

 

 
Page 4
VW Type 4 Engine:    Previous...   1 | 2 | 3 | 4 | 5 |   Next...
 
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