Disassembly and assembly of the engine (VW Golf 3)

Disassembly

Before starting work, you need to thoroughly clean the entire outer surface of the engine. Cover all engine openings with a clean cloth beforehand to prevent foreign objects from getting inside.

Engine disassembly is described in detail below. Therefore, we describe the work that is carried out either with the engine assembled or disassembled, without repeating specific disassembly operations.

If it is necessary to completely disassemble the engine, it is only necessary to combine individual operations with each other, and in the specified sequence.

Generally, when disassembling, it is important to note the position of all moving or sliding parts before disassembling, so that they can be reinstalled in their original position if they are to be used again. This is especially important for pistons, valves, bearing caps and bearing shells.





Don't mix up the parts. The flaps can be stuck into the bottom of an upturned cardboard box so that they can be numbered.

Bearing and seal surfaces should never be marked with a scriber or even a number stamp. Many parts are made of aluminum and must be handled accordingly. If some parts can only be separated by tapping, use only a rubber, plastic, or leather mallet.

If you do not have the installation diagram according to the instructions, it is best to cut out suitable wooden parts on which the engine can be placed in such a way that the upper and lower sides of the engine can be accessed. After dismantling, the cylinder head can be clamped in a vice together with the metal bracket into which the studs of the intake duct are screwed.

The following is a typical engine disassembly.

Remove all minor engine components, i.e. distributor, carburetor with intake manifold, exhaust manifold, injection system components, etc.

Unscrew the control belt protection device and remove it.

Remove the belt tensioner from the end of the engine.

Unscrew the crankshaft belt pulley together with the flywheel from the shaft.


Unscrew the water pump.

Unscrew the oil filters. Unscrew the oil cooler. placed between the oil filter and the filter base (remove the nut).

If necessary, unscrew the base from the engine.

Remove the dipstick.

Unscrew the cylinder head cover and immediately remove the seal.

Remove the cylinder head.

Turn the engine over and unscrew the oil pan. Remove the seal.

Unscrew the oil pump from the bottom of the crankcase and remove it.

Mark the cylinder numbers on the connecting rod bearing caps with paint and remove the bearing caps one by one. The two connecting rod bearings must always be at bottom dead center when the caps are disconnected. Pull the connecting rods up out of the cylinder bores one by one together with the pistons. Note that the caps and bearing shells are immediately screwed back onto the corresponding connecting rods. The connecting rod bearings are fastened with flexible screws; the screws cannot be reused.

Remove the crankshaft. In this case, mark the bearing caps with numbers (No. 1 on the belt pulley side, No.5 on the flywheel side).

Remove the intermediate shaft flywheel.

Unscrew the intermediate shaft flange and press the flange. Remove the shaft from the engine.

Assembly

When carrying out any engine assembly operation, the following provisions must be followed.

Check for foreign bodies before assembly.

Apply an oil lubricating film to all rotating or sliding parts. Do this before assembly, otherwise the oil cannot reach the bearing surfaces themselves, it is especially important to generously lubricate the pistons, piston rings and cylinder walls with machine oil before assembly.

Thoroughly clean all cylinder block parts if the engine is completely disassembled. When partially disassembling the engine, make sure that no foreign object can get into the disassembled parts of the engine or its cavities. Either seal or plug all openings with rags.

It is best to blow out the oil channels and holes with compressed air. If this is not possible, push the channels or holes with a suitable wooden object (under no circumstances metallic).

Always replace sealing rings, gaskets, etc. You cannot save on such parts and use previously damaged parts.

The table of dimensions and adjustment parameters indicates the wear limits of most moving parts. If any part is in doubt or is close to the wear limit, it is better to replace the part to avoid disassembling the mechanism again in the near future.