Install a clean cylinder block on the stand. Install the crankshaft bearing shells, lubricating them with engine oil, and install the crankshaft into the bearing seats. Install liners with oil grooves in the sockets of the cylinder block (pic. 3-1). Install the main bearing caps so that the shoulders of the upper and lower shells are opposite each other. Install the front and rear crankshaft oil seal holders. In this case, be sure to replace the seals with new ones. Assemble the pistons with the connecting rods in such a way that the lugs, the alignment marks on the connecting rod and the connecting rod cap, and the cutout in the upper part of the piston are located on one side (pic. 3-2).
The pistons of turbocharged diesel engines have a cutout for oil nozzles.
Note. It may be necessary to heat the piston to about 60°C to assemble the piston to the connecting rod. If necessary, use a mandrel for assembly.
Install the piston rings in the corresponding grooves of the piston, placing their locks through 120°. Label «Thor» («Top») on the piston rings must face the piston crown.
When assembling pistons with connecting rods, the mark on the upper head of the connecting rod must be turned towards the camshaft drive.
Lubricate the pistons and piston rings with engine oil, compress the piston rings in the grooves using a suitable mounting sleeve (pic. 3-3) and insert the pistons with connecting rods into the cylinders (pic. 3-4), orienting the arrow on the bottom of the pistons towards the camshaft drive (pic. 3-5). Install the liners in the connecting rods and connecting rod caps in accordance with the marks made during disassembly, if previously removed liners are used. Install the connecting rods and caps on the crankshaft journals in accordance with the alignment marks applied by the core. Install new connecting rod bolts, lightly tighten their nuts, then finally tighten to the specified torque. Install the cylinder head as shown below.
Warning. When installing new pistons, measure the protrusion of the pistons at TDC relative to the plane of the cylinder block (pic. 3-6), which is necessary to determine the thickness of the cylinder head gasket, as indicated in subsection «cylinder head».
Carry out the remaining engine assembly operations in the reverse order of disassembly.
Note. In the cylinder block of turbocharged diesel engines, oil nozzles are located to cool the pistons. Before installing the injectors, apply locking glue to the threads of their fastening bolts.
After removing the intermediate shaft or its thrust bearing, the oil seal and O-ring must be replaced with new ones.
Using drift VW 10 203, press new oil seal into thrust bearing.
Warning. The direction of rotation of the intermediate shaft is counterclockwise. In accordance with this, an oil seal should be installed, on the body of which an arrow of the direction of rotation of the shaft is applied.
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