When disassembling, mark the location of removable parts and parts in order to reassemble them in their original position if they are to be reused. This is especially important for pistons, valves, caps and bearing shells. Fold the parts in such a way as not to mix them up.
Never mark bearings and seals by scratching their surface or using a punch. Only a rubber, plastic or leather-covered hammer may be used to remove any part of the engine.
If the engine has been completely disassembled, thoroughly clean all parts of the cylinder block. When partially disassembling, be sure to ensure that foreign bodies do not get into unassembled parts of the engine or into its cavities. In order to prevent foreign bodies from entering, either plug all the holes with something, or cover them with rags.
Blow out all oil passages and holes with compressed air. If this is not possible, then clean these channels and holes with a piece of wood, but in no case do this with metal objects.
With the engine disassembled, pay particular attention to metal chips or other signs of excessive metal wear found inside the cylinder block.
Always replace O-rings, gaskets, etc. for new ones. Never skimp on this and never put back damaged parts.
The table with data for adjustment and control shows the wear limits of most moving parts. If there is doubt about any part, or the wear limit will soon be reached, it is better to replace such a part in order to avoid re-disassembly of the engine after a short time. Keep in mind that this data is different for different engines. Certain values are not specified «Volkswagen» in the form of nominal values. In this case, an appropriate check must be carried out.
When assembling, use the general recommendations:
- before installing the parts, make sure they are clean and free from foreign bodies;
- Apply a thin layer of lubricant to all parts that rotate or slide. This operation should be carried out before assembly, and not after the parts have already been installed, since in this case the oil will not get into all the places required for lubrication. It is especially important to generously lubricate the pistons, piston rings and cylinder walls with engine oil before assembling.
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