Diesel head assembly
The block head is assembled in the reverse order (see Fig. 191, 192).
♦ Lubricate the valve stems liberally with engine oil and insert them into their respective guides.
Rice.
191 Block head arrangement 1 - nut, 20 Nm, 2 - stud, 15 Nm, 3 - camshaft bearing cap, 4 - camshaft, 5 - hydraulic tappet, 6 - crackers, 7 - upper spring plate, 8 - outer valve spring,
9 - internal valve spring, 10 - lower spring plate, 11 - oil seal, 12 - valve guide, 13 - rear camshaft oil seal, 14 - injector, 15 - heat insulating washer, 16 - spark plug, 30 Nm, 17 - cylinder head, 18 - valve, 19 - front camshaft oil seal.
Rice.
192 Camshaft four-cylinder engine 1 - sealing washer, 2 - camshaft bearing cap, 3 - nut, 20 Nm, 4 - camshaft
♦ On the other hand, install the lower spring plate into its seat using the special tool.
♦ Install the valve stem seal. When doing this, use the tool described in the Volkswagen Transporter T4 .
♦ Reinstall the inner and outer valve springs (if old springs are being installed).
♦ Put on the spring cap and install the valve assembly tool, compress the spring.
When the end of the valve stem protrudes above the spring plate, insert both crackers into the valve groove with tongs and carefully loosen the tool lever. ♦ Check the valve lifters, install them in well lubricated holes.
It is necessary to strictly ensure that the pushers are installed according to the numbering, i.e. into the holes from which they were taken. ♦ Lubricate the camshaft journals liberally.
The remaining elements of the block head are similar to the elements of a five-cylinder engine.
The camshaft seal is in front. ♦ Fit the camshaft and rotate it several times. Install the camshaft in such a position that both cams of the first cylinder are pointing up.
Four cylinder engine
♦ Put on bearing caps no. 2 and 4 and screw on their nuts.
Since the bearing holes are not located in the middle between the bolts, after installing the covers, it is necessary to check whether their bearing holes are on the shaft neck. Tighten the nuts of the installed covers gradually and crosswise with a torque of 20 Nm. Check if the caps rest on the surface of the head. ♦ Fit bearing caps no. 1, 3 and 5, screw on the nuts and then progressively tighten them crosswise to a torque of 20 Nm.
The numbering of the camshaft bearings corresponds to that shown in fig. 192 for a gasoline engine. Five-cylinder engine
♦ Install bearing caps 2 and 4 and screw on nuts.
Check if the bearing holes in the caps are correctly installed. Tighten the cap nuts evenly to 20 Nm. ♦ Fit caps 3 and 5 in the same way as caps 2 and 3.
♦ Fit the oil seal in the same way as you install the front crankshaft oil seal.
For a five-cylinder engine, it is necessary to install the second oil seal on the other side of the block head in the same way. ♦ Mount the timing pulley on the camshaft (not forgetting the key) and screw in the mounting bolt with washer.
Hold the camshaft properly while tightening the gear bolt (e.g. with an old toothed belt). Tighten the bolt to 85 Nm for a five-cylinder engine and to 45 Nm for a four-cylinder engine.
♦ Install intake and exhaust manifolds (with new gaskets).
♦ Install four or five nozzles.
♦ Screw in the spark plugs.
♦ Replace any removed accessories.
T4 cylinder head device . T4 engine device .