Installing a piston with a connecting rod
♦ Coat the surfaces of the cylinder bores with engine oil.
♦ Arrange all connecting rod assemblies by cylinder number.
The tides on the lower head of the connecting rod and its cover, as well as the arrows on the bottoms of the pistons, must be directed towards the crankshaft belt pulley. ♦ Place the locks of the rings evenly around the perimeter, every 120º.
♦ Mount the piston ring clamp tool and push the rings completely into the piston grooves.
♦ Place pieces of rubber or plastic tubing over the connecting rod bolts to avoid damaging the cylinder liner surface during installation.
♦ Turn the crankshaft so that its two knees are at TDC.
♦ Lay the engine on its side.
In this position, it is more convenient to connect the lower head of the connecting rod and the connecting rod neck. ♦ Insert the connecting rod into the cylinder. The connecting rod half must already be in the hole in the lower end of the Volkswagen Transporter T4 .
♦ Insert the piston into the cylinder so that the rings fit into the cylinder one by one and the connecting rod end sits on the crankpin.
♦ Be sure to keep the two tides shown in Figure 99 side by side.
♦ Tighten the nuts of the connecting rod bolts in stages and in turn to 30 Nm, and then from this position, tighten a further 90º (1/4 turn).
♦ After installing the connecting rod, turn the crankshaft several times to check the quality and correct assembly.
When a noticeable resistance appears, it is necessary to find and eliminate its cause. The following cases are possible: Dirt under or on the bushing,
- Installing caps on connecting rods that do not match them,
- Turning the bushing with the shaft,
- Jamming of the piston rings.
♦ Use a feeler gauge to check the clearance between the side surface of the connecting rod end and the bearing surface of the crankshaft journal as shown in Fig. 111. This is the end play of the connecting rod and should not exceed 0.37 mm.
♦ Replace the oil sump.
Installing the Volkswagen T4 engine . Specifications for the Volkswagen Transporter .