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
2.4. Pistons and rods
2.4.1. Removal
2.4.2. Measurement of diameters of cylinders
2.4.3. Check of pistons and rods
2.4.4. Measurement of working backlashes in шатунных bearings
2.4.5. Assemblage of pistons and rods
2.4.6. Installation of 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


2.4.1. Removal

Pistons and rods are pushed out upwards from картера by means of the wooden handle of a hammer after removal of covers of bearings of rods and loose leaves of bearings. Before carrying out of these works it is necessary to familiarise with following recommendations:

Fig. 58. Marks of the bottoms of pistons before removal of pistons and rods

- On each piston and a rod corresponding to it cylinder number from which they have been dismantled should be specified. It is better to make a paint on the piston bottom (fig. 58). Besides, to put on the bottom of the piston an arrow specifying in a direction to a forward part of the engine;

Fig. 59. Marks of covers of bearings and rods before their removal

Fig. 60. The shatunnyj bearing

- Before dismantle of the piston with a rod to pay attention to an exact direction of installation of a cover of the bearing of a rod and before cover removal to put кернером on one party of a rod and a cover of the bearing cylinder number (the cylinder № 1 — one label etc.) (fig. 59). Rods and covers of bearings of rods should be packed so that both inflow In (fig. 60) and designations And numbers of cylinders were against each other. Both inflow after installation of rods should be always directed towards a pulley of a cranked shaft;
- Loose leaves of bearings to designate according to a rod and a bearing cover. In the same way on the back party a paint to designate the top and bottom loose leaves of bearings;
- Pistons differ from each other on depth of dredging in the bottom. For example, if it is supposed to establish the piston from the second-hand car it is possible to measure depth b (compression height) according to fig. 61. Its value is unequal for various engines.

Fig. 61. The sizes of the piston ("Specifications" see)

The pistons planned for installation should have identical depth. Differ on width and dredging with. Pistons of the engine in volume of 1,6 l, let out since 1996, have the same sizes, as pistons of its predecessor — the engine in volume of 1,6 l. Pistons of the engine in volume of 1,4 l already differ in the sizes from let out earlier. Therefore at use of new pistons it is necessary to measure old pistons and obtained given to compare to the data of the new.
At removal of pistons it is necessary to execute the following:
- To take out covers and loose leaves of bearings and to take details as it is specified above. If it is necessary, to remove formed on the top part of the piston a ring of an oil deposit with the help шабера;
- To push out piston fingers after removal of lock rings. Cut in an aperture for a piston finger allows to use оправку with which help it is possible to take lock rings, as is shown in fig. 62. A finger выпрессовывают approaching for this purpose оправкой;

Fig. 62. Extraction of spring lock rings from flutes in an aperture for a piston finger by means of pointed оправки

- To take out piston rings serially by means of the piston rings of special captures intended for installation, since the piston bottom (fig. 63). If rings can be used again they should be marked in appropriate way. In the absence of assembly nippers from piston opposite sides under a ring metal plates are inserted. It is necessary to enclose one of plates under a ring in a place shown on fig. 64 that was not задиров on a cylinder mirror.

Fig. 63. Extraction of piston rings by means of the special captures intended for their installation

Fig. 64. Use of metal plates for removal or installation of piston rings. After installation of plates of a ring are taken out upwards

Fig. 66. Details of the piston and a rod of the engine in volume of 1,0 l (on other engines rod bolts are rolled in it from below): 1 — piston rings; 2 — the piston; 3 — a rod; 4 — a cover of the bearing of a rod; 5 — a nut of the bearing of a rod, 30 Нм + 90 ; 6 — the loose leaf of the bearing of a rod; 7 — the block of cylinders; 8 — a rod bolt (always to replace), on engines in volume 1,3, 1,4 and 1,6 l to tighten the moment 30 Нм + 90 ; 9 — a lock ring of a piston finger; 10 — a piston finger

On fig. 66 details of the piston after dismantling are shown. Elements And and In should coincide at use of identical details.

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2.4. Pistons and rods
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2.4.2. Measurement of diameters of cylinders