Fig. 69. Cylinder block with parts installed on it: 1 - bolt, 25 Nm; 2 - cooling pump pulley; 3 - bolt, 20 Nm; 4 - cooling system pump; 5 - O-ring, always replace with a new one; 6 - oil dipstick with guide tube; 7 - oil drain lock, 5 Nm; 8 - knock sensor #2 (to adjust the ignition timing); 9 - screw, 5 Nm; 10 - Oil pump drive cover; 11 - O-ring, always replace with a new one; 12 - oil pump drive; 13 - cylinder block; 14 - intermediate shaft; 15 - adjusting washer, the inscription on it should be facing up; 16 - bolt, 10 Nm; 17 - O-ring, always replace with a new one; 18 - oil pan gasket; 19 - thermostat housing; 20 - bolt, 10 Nm; 21 - O-ring, always replace with a new one; 22 - crankshaft speed sensor; 23 - bolt, 5 Nm; 24 - bolt, 20 Nm; 25 - O-ring seal
Wash cylinder block 13 (Fig. 69) thoroughly and clean the oil passages. Blow and dry with compressed air, then inspect the cylinder block. Cracks in the bearings or other places in the cylinder block are not allowed. Be sure to remove all residues of cleaning agents from the cylinder block.
Measure the clearance between the side surfaces of the cylinder and the piston (see p. 2.4.2).
The difference in measured values of the cylinder inner diameter between the upper and lower belts indicates the conicity of the cylinder bore, and the difference in values between the longitudinal and transverse directions indicates ovality. The cylinder inner diameter should not differ anywhere more than 0.08 mm from the nominal size.
The engine can be equipped with pistons of two repair sizes, for which it is necessary to bore the cylinder block accordingly (see p. 2.4.2).
The original material is available on the portal (vwmanual.ru)
Fig. 46. Checking the cylinder head for deformation using a measuring ruler and feeler gauge
Check the cylinder block surface for deformation (as for the cylinder head see Fig. 46), to do this, measure the cylinder block clearance in the longitudinal, transverse and diagonal directions using a set of feeler gauges. The clearance should not exceed 0.10 mm. Before measuring, make sure that the cylinder block surface is thoroughly cleaned and there are no foreign bodies between the feeler gauge and the cylinder block surface.
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