When disassembling, mark the location of removable parts and components so that when reassembling, they can be installed in their original position if they are to be reused. This is especially important for pistons, valves, covers and bearing shells. Fold the parts in such a way as not to mix them up.
Never mark bearings or seals by scratching their surface or using a punch. Only a rubber, plastic or leather-covered hammer may be used to remove any engine part.
If the engine has been completely disassembled, all parts of the cylinder block should be thoroughly cleaned. When partially disassembling, be sure to ensure that no foreign bodies get into the undisassembled parts of the engine or its cavities. To prevent foreign bodies from getting in, 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 passages and holes with a piece of wood, but under no circumstances do this with metal objects.
With the engine disassembled, pay particular attention to any metal shavings or other signs of increased metal wear found inside the cylinder block.
Always replace sealing rings, gaskets, etc. with new ones. Never skimp on this and never put back damaged parts.
The adjustment and control data table shows the wear limits of most moving parts. If there is any doubt about a part or the wear limit is about to be reached, it is better to replace such a part to avoid repeated disassembly of the engine in a short time. Remember that these data differ for different engines. Specific values are not indicated "Volkswagen" in the form of nominal values. In this case, it is necessary to carry out an appropriate check.
When carrying out assembly work, use the following general recommendations:
- before installing parts, make sure they are clean and free of foreign bodies;
- apply a thin layer of lubricant to all rotating or sliding parts. This should be done before assembly, not after the parts have been installed, as this will prevent the oil from reaching all the areas that need to be lubricated. It is especially important to generously lubricate the pistons, piston rings, and cylinder walls with engine oil before assembly.
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