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Home >> Volkswagen >> 1984 >> Vanagon Base, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 1.9L Water-Cooled 4-CYL >> Crankcase, Crankshaft, & Camshaft >> Crankcase >> Reassembly

Crankcase, Crankshaft, & Camshaft: Crankcase: Reassembly

NOTE: Manufacturer states that AMV 188 000 02 Sealant ONLY is to be used when assembling crankcase halves.
  1. Clean all sealing compound off bolts, nuts and washers. If D 3 Sealant (Brownish sealant) was used previously, crankcase halves must be cleaned completely. If AMV 188 000 02 Sealant was used previously, only excess that hangs over edges should be removed. Blow out all oil galleys with compressed air. Check studs for tightness.
  2. Install oil pickup after blowing clear with compressed air, making sure pickup is tight fit in case. Make sure bearing locating dowels are snug fit in case. Install No. 2 main bearing halves and camshaft bearings in cases. Make sure bearing tangs locate properly in case grooves. Lay crankshaft, with connecting rods attached, into left case half.
  3. Make sure to properly line up main bearings and locating dowels. Install camshaft, making sure valve timing is correct. See CAMSHAFT  Installation. Install metal camshaft plug in left case after coating edge of plug with sealer. Spread thin layer of sealant (AMV 188 000 02) over mating surfaces of both halves of crankcase. Sealant dissolves previous sealant (of same type) and hardens with metal contact in absence of air.
  4. Place right half of case over through studs and press case halves together. Coat both sides of washers or faces of cap nuts with D 3 sealant and install all 8 and 10 mm nuts. Tighten 8 mm nut above and behind No. 1 exhaust lifter bore first. Tighten all 10 mm nuts and then tighten all remaining 8 mm nuts. Install distributor drive gear and distributor. See DISTRIBUTOR DRIVE INSTALLATION .
  5. Install carrier assembly, making sure arrow points to front of vehicle. Install flywheel/drive plate and both crankshaft oil seals after checking crankshaft end play. See CRANKSHAFT END PLAY .
  6. Install remaining parts in reverse order of disassembly. Always use new gaskets and sealing rings. Make sure engine develops oil pressure after starting. Bleed and top up cooling system. See WATER PUMP  Installation.
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