Head assembly
Assembly is carried out in the reverse order.
The following guidelines should be followed:
♦ Lubricate the valve stems liberally with engine oil and insert them into their respective guides.
♦ On the opposite side, install the lower spring plates on the guide and seat them in the appropriate places.
To do this, you can use the device. ♦ Install valve stem seals.
To perform this operation, the device (10-204) shown in fig. 89. The valve stem seals are installed as follows: - Put on the plastic sleeve, which is part of the tool, on the valve stem.
- Lubricate the valve stem seals with engine oil and put on the plastic bushing.
- Attach tool (3) to the valve stem seals and carefully push the caps onto the valve guide.
Installation without the help of this or any similar device may damage the valve stem seals. If the valves have been lapped, they must fall into the seats to which they were lapped.
Rice. 89 Tool for installing valve stem seals
♦ Replace the outer and inner springs and secure the top poppets to the valve stems.
♦ Lubricate the tappets liberally with engine oil, install them in the holes according to the previously marked marks on the inner walls (if using old ones) and fasten the upper poppets to the valve stems.
♦ Lubricate the camshaft journals thoroughly with engine oil.
♦ Lay the camshaft on the head supports and rotate it several times, placing both cams of the first cylinder with the lugs down.
♦ Fit bearing caps numbers 1, 3, 5 (see fig. 90) and hand tighten the nuts. Since the bearing caps are not symmetrical, check that they are installed correctly.
Rice. 90 Camshaft cover numbering
♦ Tighten the nuts of the installed covers in stages and crosswise until a tightening torque of 20 Nm is reached.
Check the correct fit of the cover on the surface of the block head. ♦ Use tool VW-3236 to loosen and tighten bolts.
♦ Install bearing caps numbers 2 and 4. Tighten the nuts in a cross pattern until a tightening torque of 20 Nm is reached.
♦ Inspect the camshaft seal and determine which side the spring is on.
♦ Guide the seal with the spring towards the inside of the block head. Lubricate the sealing lip of the oil seal and the seating surface of the Volkswagen Transporter T4 .
Attach the gland to the socket and hammer it into place. To install the stuffing box, use a piece of pipe with a diameter slightly smaller than the outer diameter of the stuffing box. ♦ Mount the gland flush with the outer surface of the head.
Rice. 91 Checking the end play of the crankshaft
♦ Install the sprocket and washer on the camshaft and tighten the mounting bolt to the recommended torque.
Lock the camshaft pulley and tighten the bolt to 80 Nm. ♦ Install the intake and exhaust manifolds (replacing their gaskets).