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


2.4.6. Installation of pistons and rods

For installation of pistons and rods it is necessary to execute the following:
- Carefully to grease a mirror of cylinders;

Fig. 60. The shatunnyj bearing

- To spread out all rods according to numbers of cylinders. Inflow on a rod and a bearing cover should be directed towards a pulley of a cranked shaft (sm fig. 60). On fig. 66 it is shown, how details should be combined;

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

- Arrows on the bottoms of pistons should specify in a forward part of the engine;
- To arrange locks of piston rings that they were equally spaced on a piston circle at an angle 120 . On fig. 66 displacement of locks in relation to a piston finger is shown;
- To establish a coupling tape collar round a piston ring, as is shown in fig. 72, and hand pressing to establish piston rings in flutes. To check up reliability of landing of rings;

Fig. 72. Installation of a coupling tape collar

- To put on rod hairpins short scraps of a rubber or plastic tube (only for the engine in volume 1,0) not to scratch a cylinder mirror;
- To turn a cranked shaft of the engine until two шатунные necks of a cranked shaft will not appear in НМТ;
- To insert from above a rod into the cylinder. To put for this purpose the engine sideways that it was possible to establish a rod on a basic neck, without supposing occurrence of scratches in the cylinder or on a neck of a cranked shaft. The loose leaf of the bearing of a rod should be in a rod, and its adjusting uvula — in a corresponding cut in a rod;
- To insert the piston into a cylinder aperture while rings serially will not enter into the channel, and the bottom head of a rod will not sit down on шатунную a neck of a cranked shaft;
- To insert the second loose leaf into a bearing cover, it is good to grease, press it a bearing cover to hairpins of a rod and slightly to knock (for the engine in volume 1,0) or to screw bolts in a rod through a cover of the bearing of a rod. In this case to oil the bottom party of heads of bolts and a carving, having removed preliminary rubber tubes (if they were used). It is obligatory to watch that both inflow have been combined with each other;
- To grease surfaces прилегания nuts to a cover of the bearing of a rod, a carving of bolts of a rod (the engine in volume 1,0). To tighten nuts or rod bolts in two steps as follows:
1) to tighten nuts or rod bolts alternately till the moment 30 Нм;
2) to tighten for 90 ;
- After rod installation to turn some times a cranked shaft to reveal jamming;
- Once again to check up a designation of all rods and to be convinced that pistons are established correctly;
- To measure with the help щупа a backlash between a lateral surface of a rod and a working surface of a cranked shaft, as is shown in fig. 73. It is an axial backlash of bearings of a rod which should not exceed 0,40 mm. Usually it makes 0,05–0,31 mm. To measure a backlash it is better before engine dismantling;

Fig. 73. Check of an axial backlash of the bearing of a rod on cranked to a shaft with the help щупа

- Further to spend works to sequences, return to removal, in summary to establish the pallet (подразд. 3.1.). Thus it is necessary to pay attention to distinction in ways of fastening (since March, 1995).

Back on page
2.4.5. Assemblage of pistons and rods
On the following page
2.5. The block of cylinders