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


2.4.5. Assemblage of pistons and rods

For assemblage of pistons and rods it is necessary to make the following:
- At replacement of pistons to be convinced that all pistons concern one type;
- To heat up pistons to temperature 60 With (to put in hot water). To pick up оправку the suitable size which can be inserted in a piston finger;
- Effort of a hand to insert the greased finger in нагретый the piston and a rod. On fig. 71 it is shown how to hold a finger. It is preliminary necessary to establish a persistent ring that it was possible to press densely a finger to it on one party;

Fig. 71. Installation of a piston finger

- At assemblage of pistons and rods it is obligatory to observe following recommendations:
1) the arrow on the piston bottom (drawn by hand or beaten out at new pistons) should be turned to the forward party of the engine (fig. 58 see);

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

Fig. 60. The shatunnyj bearing

2) inflow on a rod and covers of bearings (fig. 60 see) should be turned towards a pulley of a cranked shaft;
3) designations of numbers of cylinders (fig. 59 see) on a rod and a bearing cover should correspond each other;

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

- To establish on other party of the piston the second spring lock ring and to be convinced of reliability of its landing;
- To check up, that the piston after assemblage could bend freely every which way;
- To establish by means of nippers for installation of piston rings piston rings in flutes (fig. 63 see). Компрессионные piston rings can be mixed, therefore before installation it is necessary to pay attention to their cross-section section. Besides, these rings have on one party a designation Top or Oben, after installation of a ring it should be visible from outside the piston bottoms.

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

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2.4.4. Measurement of working backlashes in шатунных bearings
On the following page
2.4.6. Installation of pistons and rods