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
2.5. The block of cylinders
2.6. A cranked shaft and radical bearings
2.6.1. Removal of a cranked shaft
2.6.2. Check of a cranked shaft
2.6.3. Installation of a cranked shaft
2.6.4. Cuffs of a cranked shaft
2.6.5. A flywheel
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


2.6.1. Removal of a cranked shaft

For removal of a cranked shaft it is necessary to dismantle the engine for what to execute following operations:
- To disconnect a transmission from the engine. At removal of a transmission not to damage coupling;
- To dismantle coupling (подразд. 7.1);
- To fix a gear wreath of a flywheel by means of a screw-driver and to turn away fastening bolts. In most cases bolts it is possible to turn on also by means of a ring wrench without flywheel fixing. To establish for this purpose a ring wrench at right angle and to strike a hand on the key end. For coupling fixing it is possible to drill two apertures in a narrow metal strip and to fix it by means of flywheel bolts on a coupling surface. To provide a reliable support of the engine and to turn away bolts. On fig. 75 position of a metal strip is shown at отворачивании bolts

Fig. 75. Installation of a metal strip for отворачивания or tightenings of bolts of a flywheel

- Before flywheel dismantle it is necessary to put кернером labels on press a disk and a flywheel to note mutual position of these details. To turn on from outside the engine a bolt of a belt pulley of a cranked shaft, thus a flywheel still is in the fixed position;
- To dismantle a head of the block of cylinders with inlet and final collectors (подразд. 2.3.1). Dismantle of a gear belt see подразд. 2.7.1;
- To note a paint on lateral aspect a direction of rotation of a gear belt;
- To turn away the pallet (подразд. 3.1);
- To dismantle the oil pump (подразд. 3.2.1);
- If it is necessary to dismantle only a cranked shaft pistons and rods can be left in the block of cylinders. Otherwise to dismantle pistons and rods as it is described in подразд. 2.4.1. If rods and pistons remain in the block it is necessary to mark covers of bearings of rods, to remove and arrange them together with loose leaves. Not to forget about necessity of replacement шатунных bolts. It concerns bolts with nuts and without nuts (engines 1,3; 1,4 and 1,6);

Fig. 76. Measurement axial люфта a cranked shaft with the help стрелочного the indicator

- To establish стрелочный the indicator with a support so that a measuring tip it has appeared on a trailer neck of a cranked shaft (fig. 76). The indicator can be established on the block of cylinders by means of a magnetic support. To move a screw-driver a cranked shaft aside, to establish the indicator indication on zero and to move a cranked shaft to other party. The indication стрелочного the indicator should be written down for the subsequent assemblage. If axial люфт will exceed 0,20 mm it is necessary for considering at installation.
At absence стрелочного the indicator люфт it is possible to measure on the central bearing between a flange of the bearing and a surface of a cranked shaft with the help щупа, as is shown in fig. 77;

Fig. 77. Measurement axial люфта a cranked shaft on the central bearing

- Using fig. 25, to turn away fixing bolts on the forward party of the engine and to uncover with a lining;

Fig. 25. Details on the face party of the engine: 1 — the top casing of a gear belt; 2 — a gear belt; 3 — bolts, 20 Нм; 4 — a protective casing of a gear belt for a pump pulley; 5 — a bolt, 80 Нм; 6 — a gear pulley of a camshaft; 7, 8 — bolts, 10 Нм; 9 — a casing of a gear belt (inside); 10 — a sealing ring of round section; 11 — the water pump; 12 — the device of a tension of a belt; 13 — a nut, 20 Нм; 14 — the assembly console; 15 — a gear pulley of a cranked shaft; 16 — a bolt, 40 Нм + 90 ; 17 — a pulley of a cranked shaft; 18 — a bolt, 20 Нм; 19 — поликлиновой a belt; 20 — a bolt, 90 Нм + 120 ; 21 — the bottom casing of a gear belt

- Using fig. 78, to turn away bolts of a back cover and to remove it with a lining. In a cover there is a cuff with which it is impossible to replace, as on the forward end of a shaft. Probably, it is necessary to replace a cover;

Fig. 78. Details of a flywheel with back маслоуплотнительным a ring: 1 — a flange lining; 2 — a flange of a sealing ring with established маслоуплотнительным a ring; 3 — a flywheel; 4 — a flywheel bolt, 60 Нм + 90 (always to replace); 5 — a bolt of a cover of a flange, 10 Нм

- To turn on in regular intervals, cross-wise bolts of covers of bearings of a cranked shaft and to take out them serially. To check up, whether numbers of covers are well visible. The cover № 1 is from outside a pulley;
- To remove loose leaves of bearings from radical necks of a cranked shaft and to arrange them together with corresponding covers of bearings;
- To remove from a cover of the central radical bearing the persistent half rings used for adjustment axial люфта;
- To take out a cranked shaft from the block of cylinders;
- To take out the remained loose leaves from картера and to arrange them together with other loose leaves and covers. Loose leaves have flutes for greasing, at assemblage again it is necessary to establish them in картер. To take out the bottom persistent half rings of the central bearing and to arrange them according to the installation party together with other adjusting washers.

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2.6. A cranked shaft and radical bearings
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2.6.2. Check of a cranked shaft