Contact surfaces and gaskets
Wherever there is a gasket between two contact surfaces, it must be replaced with a new one during installation. Unless otherwise specified, it must be dry and not greased. It is necessary to check that the contact surfaces are clean and dry, so that all traces of the old gasket are removed. A scraper that does not damage the surface must be used to clean the contact surfaces. Burrs and scratches must be removed with a whetstone or a fine file. Threaded holes must be cleaned with a tap. Unless otherwise specified, sealing substances must be used in them. All holes, channels and tubes must be blown out (best with compressed air).
Seals
The seal, removed separately or as part of a set, must be replaced with a new one each time. It is very easy to damage the thin lip of the seal if the surface it contacts is not perfectly clean and free of scratches. It is necessary to protect the seal from damage, for example, a sharp edge of the surface can damage it during installation. Where possible, tape or a plastic sleeve must be used. Before installing the seal, it is necessary to cover its lips with oil, and in the case of a seal with two lips, fill the space between them with grease. Unless otherwise specified, seals must be installed with the sealing lips in the direction of the element to be sealed. To install the seal, it is necessary to use a tube of the appropriate diameter or a wooden block of the appropriate size and, if the seal seat is turned, press the seal until it stops.
If the seal seat is not turned, the seal is inserted so that its surface is flush with the surface of the housing into which it is pressed.
Threads and connections
Before tightening the bolts, make sure that there is no oil or other liquid left in the blind holes with threads. Neglecting this may cause a crack in the housing due to the pressure created when tightening the bolt or gear with threads.
When checking and tightening a nut or bolt to a certain torque, it is necessary to loosen the nut or bolt by a quarter of a turn and then tighten it to a certain torque.
A spacer must be placed under the locknuts, retaining plates and washers between each fastener and the surface to which they are bolted. Always replace the spring washers with new ones. Retaining plates, which are bent to hold the nut or bolt, must also be replaced. VW recommends replacing the self-locking nuts every time.
The cotter pins must always be replaced with new ones, and their size must correspond to the size of the given hole.
(View the original article on the resource www.vwmanual.ru)
Tools and organization to make your work easier
A good tool is the basis for high-quality performance of safety and repair work.
For a car owner who does not have any tools, buying one will be a significant expense. However, if the tool is of high quality, it will serve for many years.
A novice mechanic should have a set of tools for minor repair and safety work and do simple work on the car. Along with the acquisition of experience, he can take on more complex operations, buying additional tools. Thus, a set of tools for minor repair and safety work can be increased to a set that allows repair and maintenance without a one-time large financial outlay. An experienced amateur will have a good enough set of tools to perform most repairs, while at the same time adding tools from the special category when he is convinced that the expense is justified by the use of this tool.
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