Volkswagen Polo 3 with 1994 for 2001 of release.
1. The general data
2. The engine
2.1. Removal and engine installation
2.2. Dismantling and engine assemblage
2.3. A head of the block of cylinders and valves
2.3.1. Removal of a head of the block of cylinders at the established engine
2.3.2. Dismantling of a head of the block of cylinders
2.3.3. Дефектовка and repair of a head of the block of cylinders and its details
2.3.4. Assemblage of a head of the block of cylinders
2.3.5. Installation of a head of the block of cylinders
2.3.6. Hydraulic pushers
2.3.7. Replacement of a cuff of a camshaft
2.4. Pistons and rods
2.5. The block of cylinders
2.6. A cranked shaft and radical bearings
2.7. A drive газораспределительного the mechanism
2.8. System of release of the fulfilled gases (ОГ)
3. Greasing system
4. Cooling system
5. Systems of injection of fuel
6. Ignition system
7. Coupling
8. A mechanical transmission
9. A drive of wheels
10. A steering without the amplifier
11. A steering with the hydraulic amplifier
12. A forward suspension bracket
13. A back suspension bracket
14. Brake system
15. An electric equipment
16. Heating and ventilation system
17. An automatic transmission
18. Appendices
 











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2.3.2. Dismantling of a head of the block of cylinders

Dismantling of a head of the block of cylinders is necessary for spending as follows:


Fig. 31. Details on the face party of the engine, subject to removal before dismantle of a head of the block of cylinders: 1 — the top casing; 2 — a gear belt; 3 — a bolt, 80 Нм; 4 — a camshaft gear wheel; 5 — an internal protective casing; 6 — bolts, 10 Нм; 7 — the mechanism of a tension of a gear belt; 8 — a nut, 20 Нм; 9 — a bolt, 10 Нм; 10 — ременный a pulley; 11 — a bolt, 20 Нм; 12 — поликлиновой a belt; 13 — bolts, 10 Нм; 14 — the bottom casing




- To disconnect all auxiliary details of a head of the block of cylinders (fig. 31);
- To fix in a vice a head of the block of cylinders with a collar fixed on hairpins of a final collector;
- Using fig. 32, cautiously serially to turn away bolts of covers of bearings № 5, 1 and 3 on each party and to disconnect covers. In the same way to turn out both bolts 1 (fig. 33) from a forward cover;

Fig. 32. The Camshaft in installation position (bearings are numbered): And — a wide ledge; In — numbers of covers




Fig. 33. The Camshaft with covers of bearings: 1 — a bolt, 10 Нм; 2 — a nut, 6 Нм + 90 ; 3 — a bearing cover; 4 — a camshaft




- To turn on nuts of covers of bearings № 2 and № 4 follows so that for each pass of a nut turned away on two turns until it will be possible to disconnect both covers. To remove covers and to take out a camshaft. To examine covers. The wide ledge And (fig. 32 see) is on the party of an admission of the engine. Cover number () should be visible from outside release;
- To take out pushers. They should be marked. Is better to put marks by lines on an inside, for example: the first pusher — one line, the second — two lines etc. At placing pushers to establish on their basic plane that oil in them did not change the position. This work begins with the forward party of the engine;

Fig. 34. Extraction of valves and springs of valves by means of a stripper




- The special tool which is used according to fig. 34 is necessary for dismantle of valves according to the instruction. The pusher of tool VW 541/1 presses on the top plate of a spring until springs will not appear compressed so that by means of nippers it was possible to take out crackers of fastening of the top plate of a spring. The tool pusher should enter in landing nests of springs of valves as differently it is impossible to compress a spring. For dismantle of valves it is possible to use also a pipe piece, насаженный on the top plate of a spring. To provide a good support for a spring plate on other party. To strike sharp blow by a hammer to a pipe so that to liberate crackers: they will fall in a pipe. The pipe should adjoin to a spring plate that crackers were not lost densely;
Fig. 35. The Assembly diagramme of a head of the block of cylinders without a camshaft: 1 — a hollow cylindrical pusher; 2 — crackers; 3 — the top plate of a spring of the valve; 4 — a valve spring; 5 — the directing plug of the valve with a fillet (spare part); 6 — маслоотражательный a valve cap; 7 — the established directing plug of the valve; 8 — a sealing ring of a camshaft; 9 — a head of the block of cylinders; 10 — valves; 11 — a bolt, 20 Нм; 12 — elevating скоба the engine; 13 — bolts, 20 Нм; 14 — directing for a high voltage wire; 15 — elevating скоба the engine




- To take out plates of springs and a spring. To remove маслоотражательные caps of cores of valves, it is necessary to replace them at the subsequent installation. Нарис. 35 details of a head of the block of cylinders without a camshaft are shown. It is necessary to pay attention on poses. 5 is a directing plug of the valve with a ledge;
- If it is necessary, to disconnect both elevating скобы 12 both 15 and directing for a high voltage wire to a spark plug from a head of the block of cylinders;
- To remove a cuff of a camshaft from the shaft end.



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2.3.1. Removal of a head of the block of cylinders at the established engine
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2.3.3. Дефектовка and repair of a head of the block of cylinders and its details