Aircooled VW End Play Measurement Tool

thingiverse

This is my version of the air-cooled engine end play measurement tool. This tool measures the end play with feeler gauges instead of a dial indicator. It is based on a popular design that is sold at various VW sites. Below are the directions for using this tool. Use PETG, not PLA as it will come into contact with engine chemicals. No supports or rafts are needed to print. After printing, clean out the threads. Screw in one end of the 8mm threaded rod into bottom of the tool body, put the jamb nut on the 6mm bolt and screw the bolt from the top into the tool body. The 8mm nut secures the tool to the engine when it is mounted on the engine mounting hole. See the assembled picture for reference. 1. Start with the flywheel attached to the engine and torqued to the correct amount. 2. Clean the engine case around one of the top bolt holes used for connecting the engine to the transaxle so that this tool has a clean and even surface for attachment. 3. Use the 8mm bottom threaded rod to attach the tool to the engine case through the top hole you just cleaned. Back out the smaller 6mm bolt so that it is not hitting or touching the flywheel. 4. With the crank pulley belt removed, push the pulley in toward the engine. This moves the flywheel out away from the case. 5. Tighten gently, with your fingers, the 6mm top bolt until it just touches the flywheel. Also with your fingers, turn down the jam nut so that it is just snug enough to keep the 6 mm bolt from turning accidentally. 6. Without rotating the crankshaft, pull the pulley away from the case which moves the flywheel in toward the case. This creates a gap between the flywheel and the 6mm bolt. 7. Measure the gap between the flywheel and 6mm bolt with a feeler gauge set. Start with the smallest size slipping it through the gap. Work your way up in sizes until you find the correct gap, i.e. feel a slight drag on the feeler gauge. This gap measurement is the end play measurement. 8. Adjust the end play to between .003 to 0.005 inches by using a suitable combination of 3 shim rings. Check your engines specifications for your applicable end play.